Note: Descriptions are shown in the official language in which they were submitted.
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DOOR CLOSER ASSEMBLY
BACKGROUND
[0001] The application relates to the field of door closers, and more
particularly
concerns varying the force applied to a door by a door closer depending on the
position of the
door.
[0002] Door closers are used to automatically close doors, saving people
who pass
through the doorway the effort of closing the door and helping to ensure that
doors are not
inadvertently left open. In general, a door closer may be attached to the top
of a door, and a
pivotable arm extends from the door closer to a door frame or wall. When the
door is
opened, the door closer automatically generates a mechanical force that
actuates the arm,
causing the arm to close the door without any manual application of force.
[0003] Many conventional door closers are designed to apply varying
forces to a door
as a function of the door angle, meaning the angle at which the door is open
relative to the
door frame. A door and a door closer may be considered to experience an
opening cycle and
a closing cycle. With respect to the opening cycle, the door starts in the
fully closed or home
position, typically where the door is at a door jamb. When the door is opened,
the door closer
generates little force until the door reaches a certain predetermined door
angle, which may be
designated as the beginning of a back check region. As the door enters the
backcheck region,
the door closer applies force to the door. This force slows the progress of
the door,
increasing the force required to open the door further, and may help to
prevent the door from
hitting a wall or otherwise opening past a desired stop point. Increase in
force applied by a
door closer at other points between the home position and the beginning of the
backcheck
region may be included as a feature of a particular door closer. Therefore, as
the door angle
increases or, in other words, as the door is opened wider, it becomes more
difficult to
continue pushing the door open, usually for protection of an adjacent wall.
[0004] When the door is released by the user, for example, from the fully
opened
position, the force generated by the door closer begins the closing cycle. The
door may pass
through the backcheck region and to the beginning of a latch region, proximate
to the home
position, with a substantially constant force applied by the door closer. As
the door reaches
the beginning of the latch region, very little or no force is applied to the
door. If calibrated
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correctly, the latch region allows the door to close without slamming the door
or damaging
the door frame. Reduction in the force applied by a door closer at other
points between the
fully open position and the latch region may be included as a feature of a
particular door
closer.
[0005] Many conventional door closers are mechanically actuated and have a
piston
and a plurality of springs and valved ports. The piston moves through a
reservoir filled with
a hydraulic fluid, such as oil. The piston is coupled to the door closer's arm
such that, as the
door is opened, the piston is moved in one direction and, as the door is
closed, the piston is
moved in the opposite direction. As the piston moves, it displaces hydraulic
fluid, which may
be forced through various valved ports. By allowing, limiting, or preventing
flow of
hydraulic fluid, the valved ports control the varying amounts of force applied
to the door as a
function of door angle. The piston may either cover or expose individual ports
to make flow
of hydraulic fluid through the ports possible depending position of the
piston, as determined
by the door angle. The force exerted by the door closer depends on the open or
closed status
of the ports.
[0006] The door's opening and closing profile can be controlled by
adjusting the
valves, which may often be done by turning a screw to alter the flow
characteristics through
the valve and thereby control the force applied by the closer. However, this
adjustment may
be problematic in that the valves interact and changing the setting of one
valve generally
affects the flow rates through the other valves. Many conventional door
closers implement
undesirable closing characteristics because installers may be unwilling or
unable to manually
adjust the valve settings in a desired manner, or installers may be unaware
that the valve
settings can be changed in order to effectuate a desired closing profile.
[0007] Accordingly, there exists a need for a door closer that
automatically adjusts
after initial calibration, resulting in a door motion that has desirable
opening and closing
cycles and is relatively easy to install.
SUMMARY
[0008] A door closer assembly is provided for automatically moving a door
in a
closing direction. The door is positioned within a door frame and hinged along
one edge to
the door frame for movement between a closed position and an open position.
The door
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closer assembly comprises a housing having a first end and a second end and
defining an
interior cavity. A pinion is journaled in the housing for rotation about an
axis. The pinion
includes gear teeth and at least a portion of the pinion extends from the
housing and is
adapted to be connected to turn with the door. A piston having a first end and
a second end is
slidably disposed in the cavity in the housing and divides the cavity into a
first variable
volume chamber between the first end of the housing and the first end of the
piston and a
second variable volume chamber between the second end of the housing and the
second end
of the piston. The piston has an opening defined by rack teeth for engaging
the gear teeth on
the pinion for cooperating with the pinion for converting rotation of the
pinion into linear
movement of the piston relative to the housing. Spring means are disposed in
the housing
between the second end of the housing and the second end of the piston for
urging the piston
toward the first end of the housing in the door closing direction. A passage
defined in the
housing for permits flow of fluid between the first variable volume chamber
and the second
variable volume chamber in response to movement of the piston relative to the
housing. A
valve is disposed in the passage. The valve regulates an amount of hydraulic
fluid that flows
through the valve, the amount of hydraulic fluid flowing through the valve
controlling a force
generated by the door closer assembly on the door. A first sensor measures an
angular
position of the door, and a second sensor measures a position of the valve. A
controller is
provided for controlling the position of the valve. Upon rotation of the
pinion in the door
opening direction the piston moves toward the second end of the housing
forcing fluid from
the second variable volume chamber through the passage to the first variable
volume
chamber and compressing the spring means for storing energy. The spring means
urges the
piston toward the first end of the housing for forcing fluid from the first
variable volume
chamber to the second variable volume chamber and rotating the pinion in the
door closing
direction. The controller controls the position of the valve based on the
sensed angular
position of the door and the position of the valve for determining the amount
of hydraulic
fluid flowing through the valve.
BRIEF DESCRIPTION OF DRAWINGS
[0009] For a more complete understanding of the present invention,
reference should
now be had to the embodiments shown in the accompanying drawings and described
below.
In the drawings:
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[0010] FIG. 1 is cut-away perspective view of an embodiment of a door
closer
assembly in position on a door.
[0011] FIG. 2 is an exploded perspective view of the door closer assembly
shown in
FIG. 1.
[0012] FIG. 3 is an exploded perspective view of an embodiment of a door
closer for
use with the door closer assembly shown in FIG. 1.
[0013] FIG. 4 is an end view of the assembled door closer assembly as
shown in FIG.
1.
[0014] FIG. 5A is a longitudinal cross-section view of the assembled door
closer
assembly taken along line 5-5 of FIG. 4 with the door in a closed position.
[0015] FIG. 5B is a close-up view of a portion of the assembled door
closer assembly
as shown in FIG. 5.
[0016] FIG. 6 is a longitudinal cross-section view of the assembled door
closer
assembly taken along line 6-6 of FIG. 4 with the door in a closed position.
[0017] FIG. 7 is a longitudinal cross-section view of the assembled door
closer
assembly as shown in FIG. 5 with the door in an open position.
[0018] FIG. 8 is an exploded perspective view of an embodiment of a valve
assembly
for use with the door closer as shown in FIG. 3.
[0019] FIG. 9 is an inner end view of the assembled valve assembly as
shown in FIG.
8.
[0020] FIG. 10 is an outer end view of the assembled valve assembly as
shown in
FIG. 8.
[0021] FIG. 11 is a longitudinal cross-section view of the valve assembly
taken along
line 11-11 of FIG. 9.
[0022] FIG. 12 is a longitudinal cross-section view of the valve assembly
taken along
line 12-12 of FIG. 9.
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[0023] FIGs. 13A and 13B are transverse cross-section views of the valve
assembly
taken along line 13-13 of FIG. 10 with the valve in a closed position.
[0024] FIG. 13C is a close-up view of a portion of the valve shaft and
valve sleeve in
a position shown in FIGs. 13A and 13B.
[0025] FIGs. 14A and 14B are transverse cross-section views of the valve
assembly
taken along line 14-14 of FIG. 10 with the valve in an open position.
[0026] FIG. 15 is a longitudinal cross-section view of the valve assembly
taken along
line 15-15 of FIG. 10.
[0027] FIG. 16 is a perspective view of an embodiment of a drive unit for
use with
the door closer assembly as shown in FIG. 1.
[0028] FIG. 17 is an exploded perspective view of the drive unit as shown
in FIG. 16.
[0029] FIG. 18 is a perspective view of the drive unit as shown in FIG. 16
with the
cover removed.
[0030] FIG. 19 is a perspective view of the drive unit as shown in FIG. 18
with the
COS 164 coupler removed.
[0031] FIG. 20 is a partially exploded perspective view of the drive unit
as shown in
FIG. 19 with the mounting bracket removed.
[0032] FIG. 21 is a front plan view of an embodiment of a motor coupler
for use with
the drive unit as shown in FIG. 16.
[0033] FIG. 22 is an elevated perspective view of an embodiment of a COS
164
coupler operatively connected to the motor coupler as shown in FIG. 21.
[0034] FIG. 23 is a perspective view of an embodiment of a rotatable motor
cover for
use with the drive unit as shown in FIG. 16.
[0035] FIG. 24 is a partial view of a cross-section of the drive unit as
shown in FIG.
16 taken along line 24-24 of FIG. 23.
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[0036] FIG. 25 is perspective view of an inner surface of an embodiment of
a PCB
board for use with the drive unit as shown in FIG. 16.
[0037] FIG. 26 is a partial perspective end view of the assembled door
closer
assembly as shown in FIG. 1 with the motor cover removed.
[0038] FIG. 27 is a partial perspective end view of the assembled door
closer
assembly as shown in FIG. 26 with another embodiment of a motor cover.
[0039] FIG. 28 is a perspective view of an embodiment of a control unit
for use with
the door closer assembly as shown in FIG. I.
[0040] FIG. 29 is an exploded perspective view of the control unit as
shown in FIG.
28.
[0041] FIG. 30 is a block diagram of an embodiment of a printed circuit
board for use
in a control unit for controlling a valve of a door closer.
[0042] FIG. 31 is a partially exploded perspective view of a portion of
the control unit
as shown in FIG. 29.
[0043] FIG. 32 is an exploded bottom perspective view of an embodiment of
a power
generator portion of the control unit as shown in FIG. 29.
[0044] FIG. 33 is an exploded top perspective view of the power generator
portion of
the control unit as shown in FIG. 32.
[0045] FIG. 34 is a partial bottom plan view of the power generator
portion of the
control unit as shown in FIG. 32.
[0046] FIG. 35 is a longitudinal cross-section view of the power generator
taken
along line 35-35 of FIG. 34.
[0047] FIG. 36 is partial top plan view of the power generator portion of
the control
unit as shown in FIG. 32.
[0048] FIG. 37 is a longitudinal cross-section view of the power generator
taken
along line 37-37 of FIG. 36.
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[0049] FIG. 38 is a partially exploded perspective view of an embodiment
of an
encoder portion of the control unit as shown in FIG. 29.
[0050] FIG. 39 is an exploded top perspective view of the encoder portion
of the
control unit shown in FIG. 29.
[0051] FIGs. 40A and 40B are bottom and top perspective views,
respectively, of an
embodiment of a drive gear for use with the control unit as shown in FIG. 29.
[0052] FIG. 41 is an embodiment of a circuit diagram for providing power
to various
electrical components of a door closer.
[0053] FIG. 42 is partial top plan view of the encoder portion of the
control unit as
shown in FIG. 28.
[0054] FIG. 43A is a longitudinal cross-section view of the encoder
portion of the
control unit taken along line 43-43 of FIG. 42 with a teach button in a first
position.
[0055] FIG. 43B is a longitudinal cross-section view of the encoder
portion of the
control unit taken along line 43-43 of FIG. 42 with the teach button in a
second position.
[0056] FIG. 44 is a flow diagram of an embodiment of a process for using a
teach
mode of a door closer, presented as FIGs. 44A, 44B and 44C.
[0057] FIG. 45 is a diagram of a calibration curve.
[0058] FIG. 46 is a diagram of a motor encoder calibration curve.
[0059] FIG. 47 is a flow diagram of an embodiment of a process for arm
encoder
calibration, presented as FIGs. 47A and 47B.
[0060] FIG. 48 is a flow diagram of an embodiment of a process for
calibration of a
valve encoder with respect to valve position, presented as FIGs. 48A, 48B and
48C.
[0061] FIG. 49 is a flow diagram of an embodiment of a process for
operating a
controller, presented as FIGs. 49A, 49B, 49C, 49D', 49D", 49E', 49E", 49F' and
49F".
[0062] FIG. 50 is a perspective end view of a portion of a control unit
including an
embodiment of user input switches.
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DESCRIPTION
[0063] Terminology used herein is for the purpose of describing particular
embodiments only and is not intended to be limiting of the invention. As used
herein, the
singular forms "a", "an" and "the" are intended to include the plural forms as
well, unless the
context clearly indicates otherwise. It will be further understood that the
terms "comprises"
or "comprising," when used in this specification, specify the presence of
stated features,
steps, operations, elements, or components, but do not preclude the presence
or addition of
one or more other features, steps, operations, elements, components, or groups
thereof.
Additionally, comparative, quantitative terms such as "above", "below",
"less", "greater", are
intended to encompass the concept of equality, thus, "less" can mean not only
"less" in the
strictest mathematical sense, but also, "less than or equal to."
[0064] It should also pointed out that references made in this disclosure
to figures and
descriptions using positional terms such as, but not limited to, "top",
"bottom", "upper,"
"lower," "left", "right", "behind", "in front", "vertical", "horizontal",
"upward," and
"downward", etc., refer only to the relative position of features as shown
from the perspective
of the reader. Such terms are not meant to imply any absolute positions. An
element can be
functionally in the same place in an actual product, even though one might
refer to the
position of the element differently due to the instant orientation of the
device. Indeed, the
components of the door closer may be oriented in any direction and the
terminology,
therefore, should be understood as encompassing such variations unless
specified otherwise.
[0065] As used herein, the term "open position" for a door means a door
position
other than a closed position, including any position between the closed
position and a fully
open position as limited only by structure around the door frame, which can be
up to 180
from the closed position.
[0066] The present disclosure generally relates to systems and methods for
controlling of door closers. For example, the door closer may be controlled so
that when a
first predefined door angle such as, for example, 50 degrees is reached, the
door closer
increases the force applied to the door. The force applied to the door as the
door is opened
wider may remain substantially constant until another predefined angle such
as, for example,
70 degrees is reached, at which point an even greater force is applied to the
door. The force
may be similarly increased for other predefined door angles. As the door angle
increases or,
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in other words, as the door is opened wider, it generally becomes more
difficult to continue
pushing the door open. Such a feature helps to prevent the door from hitting a
door stop or
other object, such as a wall, with a significant force thereby helping to
prevent damage to the
door or the object hit by the door.
[0067] When the door is released by the user, the force generated by the
door closer
begins to push the door closed. As the door reaches the predefined angles
described above,
the force applied to the door decreases. Thus, initially, when the door has
been opened wide,
there may be a relatively significant force applied to the door, thereby
helping to start moving
the door to the closed position. However, at each predefined angle, the force
applied to the
door by the door closer decreases. Thus, as the door angle decreases or, in
other words, as
the door is closing, the force applied to the door generally decreases as a
function of door
angle. Indeed, by the time the door is about to fully close, the force applied
to the door is
sufficiently small to prevent damage to the door when the door contacts the
door frame.
Further, having a relatively small amount of force applied to the door at
small door angles
helps to prevent injury to a user in the event that a finger, arm, foot, or
other body part is
struck by the door as the door closes.
[0068] In one embodiment, a door closer has a valve that is electrically
actuated such
that the position of the valve can be dynamically changed during operation.
Thus, as a door
opens and closes, the valve position can be changed in order to provide
varying levels of
hydraulic resistance as a function of door angle, so that only one valve is
strictly necessary to
provide such varying levels of resistance. Further, a desired closing profile
can be reliably
and precisely implemented without a user having to manually adjust the
positions of a
plurality of valves.
[0069] Referring now to the drawings, wherein like reference numerals
designate
corresponding or similar elements throughout the several views, a door closer
assembly
according to the present invention is shown and generally designated at 80.
Referring to FIG.
1, the door closer assembly 80 is mounted to a door 82 in a door frame 84. The
door 82 is
movable relative to the frame 84 between a closed position and an open
position. For the
purpose of this description, only the upper portion of the door 82 and the
door frame 84 are
shown. The door 82 is of a conventional type and is pivotally mounted to the
frame 84 for
movement from the closed position, as shown in FIG. 1, to an open position for
opening and
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closing an opening through a building wall 86 to allow a user to travel from
one side of the
wall to the other side of the wall.
[0070] As shown in FIGS. 1 and 2, an embodiment of a door closer assembly
80
comprises a door closer 90, including a linkage assembly 92 for operably
coupling the door
closer assembly 80 to the door frame 84, a drive unit 100, and a control unit
110. As seen in
FIG. 2, ends of a rotating pinion 112 extend from the top and bottom of the
door closer 90 for
driving the linkage assembly 92 to control the position of the door 82. FIG. 1
shows a
linkage assembly 92 for a push side mounting of the door closer assembly 80 to
the door 82,
comprising a first rigid connecting arm link 94 and a second rigid connecting
arm link 96.
The first connecting arm link 94 is fixed at one end for rotation with the
upper end of the
pinion 112 (FIG.1) and at the other end is pivotally connected to an end of
the second
connecting arm link 96. The other end of the second connecting arm link 96 is
pivotally
joined to a mounting bracket 98 fixed to the door frame 84. A linkage assembly
for a pull
side mounting (not shown) of the door closer assembly 80 to the door 82 is
also suitable.
Both push side and pull side mounting of the linkage assemblies are well known
in the art.
Further, it should be understood that the linkage assembly 92 for use in the
present invention
may be any arrangement capable of linking the door closer 90 to the door 82 in
such a
manner that the door closer assembly 80 affects movement of the door 82. Thus,
numerous
alternative forms of the linkage assembly 92 may be employed.
[0071] The door closer assembly 80 is securely mounted to the upper edge
of the door
82 using mounting bolts (not shown), or other fasteners. The door closer
assembly 80
extends generally horizontally with respect to the door 82. The drive unit 100
and the control
unit 110 are fixed to the door closer 90. A cover (not shown) attaches to the
door closer
assembly 80. The cover serves to surround and enclose the components of the
door closer
assembly 80 to reduce dirt and dust contamination, and to provide a more
aesthetically
pleasing appearance. It is understood that although the door closer assembly
80 is shown
mounted directly to the door 82, the door closer assembly 80 could be mounted
to the door
frame 84 or to the wall adjacent the door frame 84 or concealed within the
wall 86 or the door
frame 84. Concealed door closer assemblies are well known in the art of
automatic door
closer assemblies.
[0072] The door closer 90 is provided for returning the door 82 to the
closed position
by providing a closing force on the door 82 when the door is in an open
position. The door
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closer 90 includes an internal return spring mechanism such that, upon
rotation of the pinion
112 during door 82 opening, the spring mechanism will be compressed for
storing energy. As
a result, the door closer 90 will apply on the linkage assembly 92 a moment
force which is
sufficient for moving the door 82 in a closing direction. The stored energy of
the spring
mechanism is thus released as the pinion 112 rotates for closing the door 82.
The closing
characteristics of the door 82 can be controlled by a combination of the
loading of the return
spring mechanism and the controlled passage of fluid through fluid passages
between
variable volume compartments in the door closer housing, as described more
fully below.
[0073] FIGs. 3-7 depict an embodiment of the door closer 90. The door
closer 90
comprises a housing 114 defining an internal chamber which is open at both
ends. The
chamber accommodates the pinion 112, a piston 116, a spring assembly 118, and
a valve
assembly 120. The housing 114.
[0074] The pinion 112 is an elongated shaft having a central gear tooth
portion 122
bounded by intermediate cylindrical shaft portions 124. The pinion 112 is
rotatably mounted
in the door closer housing 114 such that the pinion 112 extends normal to the
longitudinal
axis of the housing 114. The intermediate cylindrical shaft portions 124 of
the pinion 112 are
rotatably supported in bearings 126 each held between an inner washer 128 and
an outer
retaining ring 130 disposed within opposed annular bosses 132 formed on the
top surface and
the bottom surface of the housing 114. The outer ends of the shaft of the
pinion 112 extend
through the openings in the bosses 132 and outwardly of the housing 114. The
ends of the
pinion 112 are sealed by rubber u-cup seals 134 which fit over the ends of the
pinion 112 and
prevent leakage of a hydraulic working fluid from the chamber of the housing
114. The
periphery of the bosses 132 are externally threaded for receiving internally
threaded pinion
seal caps 136.
[0075] The spool-shaped piston 116 is slidably disposed within the chamber
of the
housing 114 for reciprocal movement relative to the housing 114. In this
arrangement, as
shown in the FIGs. 5-7, the piston 116 divides the chamber in the housing 114
into a first
variable volume chamber 148 between one end of the piston 116 and the valve
assembly 120
and a second variable volume chamber 150 between the other end of the piston
116 and the
spring assembly 118. The central portion of the piston 116 is open and defines
opposed rack
teeth 117. The pinion 112 is received in the open central portion of the
piston 116 such that
the gear teeth 122 on the pinion 112 engage the rack teeth 117 in the piston
116. It is thus
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understood that rotation of the pinion 112 will cause linear movement of the
piston 116 by
interaction of the gear teeth 122 and the rack teeth 117 in a conventional
manner known in
the art.
[0076] The spring assembly 118 comprises two compression springs 138, one
nested
inside the other and supported between the piston 116 and an end plug assembly
140. The
end plug assembly 140 includes an end plug 142, an adjusting screw 144, and a
retaining ring
146. The end plug 142 is an externally threaded disc sealingly secured in the
threaded
opening in the end of the housing 114. The end plug 142 is sealed to the wall
of the housing
114 with the retaining ring 146 disposed in a circumferential groove on the
periphery of the
end plug 142. The end plug 142 thus effectively seals the end of the housing
114 against
leakage of fluid. The adjusting nut 144 is held in the housing 114 between the
springs 138
and the end plug 142. The springs 138 urge the piston 116 towards the left end
of the
housing 114, as seen in FIGs. 5-7. The adjusting nut 144 is accessible by tool
from the end of
the housing 114, and rotating the adjusting nut 144 sets the initial
compressed length of the
springs 138.
[0077] A fluid medium, such as hydraulic oil, is provided in the chamber
in the
housing 114 to cooperate with the piston 116. The end of the piston 116
adjacent the first
variable volume chamber 148 includes a centrally located check ball assembly
152 and has a
circumferential groove for accommodating a u-cup seal 154 which seats against
the inside
wall of the housing 114. The other end of the piston 116 adjacent the second
variable volume
chamber 150 is closed and sealed relative to the inside wall of the housing
114 to prevent
passage of fluid, except in the area of a longitudinal groove 156 (FIG. 5A) of
pre-determined
length in the inside wall of the housing 114.
[0078] The valve assembly 120 is sealingly disposed in the opening in the
end of the
housing 114 adjacent the piston 116. Referring to FIGs. 8-15, the valve
assembly 120
comprises a valve housing 160, a valve sleeve 162, a valve shaft 164 and a
spool plate 166.
The valve housing 160 is a cylindrical member including a relatively short
cylindrical axial
projection 168 at an outer end. The valve housing 160 defines a central axial
opening 170
therethrough. The outer end of the valve housing 160 defines a portion of the
opening 161
having a smaller diameter than the remainder of the opening thereby forming a
shoulder 171
(FIGs. 11, 12 and 15) in the axial opening 170 adjacent the outer end of the
valve housing
160. The inner end of the valve housing 160 has six spaced axial bores 172,
174, 176, 178 in
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the inner surface of the valve housing. Three equally spaced bores 172 are
threaded screw
holes for receiving screws 173 for securing the spool plate 166 to the valve
housing 160. The
remaining three bores 174, 176, 178 are fluid passages. Spaced circumferential
grooves 180
are provided in the periphery of the valve housing 160 for receiving o-rings
182. The
grooves 180 define an intermediate circumferential surface onto which radial
passages 184,
186, 188, 190, 192 open (FIGs. 13 and 14). Four of the radial passages 184,
186, 188, 190
are drilled through to the central axial opening 170.
[0079] The cylindrical valve sleeve 162 fits into the axial opening 170 in
the valve
housing 160. The valve sleeve 162 defines a central axial opening 163
therethrough. The
valve sleeve 162 has four equally, circumferentially spaced radial openings
194 opening into
the central axial opening 163. The valve sleeve 162 has a second smaller axial
passage 196
therethrough (FIG. 15). A small radial bore 198 in the periphery of the valve
sleeve 162
connects to the second axial passage 196. The valve sleeve 162 fits into the
valve housing
160 such that each of the radial openings 194 is aligned with one of the pass
through radial
openings 184, 186, 188, 190 in the valve housing 160. As best seen in FIG. 11,
one
corresponding set of the openings 188, 194 in the housing 160 and sleeve 162
is sized to
receive a hollow pin 200 for locking the valve sleeve 162 to the valve housing
160.
[0080] The cylindrical valve shaft 164 is journaled inside the valve
sleeve 162. The
outer end of the valve shaft 164 carries a cut off screw 202 with a square
end. Opposed
partial circumferential grooves 204, 205 are provided intermediate the ends of
the valve shaft
164. The valve shaft 164 is configured such that when the valve shaft 164 is
disposed inside
the valve sleeve 162, the grooves 204, 205 are at the same relative axial
position as the radial
openings 194 in the valve sleeve 162.
[0081] The spool plate 166 is attached to the inner surface of the valve
housing 160
using screws 173 threaded into the three passages 172 in the valve housing 160
for holding
the valve sleeve 162 in place. The inner surface of the spool plate 166 has a
depression 206
(FIG. 15) which is aligned with the second axial passage 196 in the valve
sleeve 162 when
the spool plate 166 is secured to the valve housing 160 for fluid transfer
during high pressure
situations, as will be described below.
[0082] The valve assembly 120 fits into the end of the housing 114 (FIGs.
3, 5-7).
Each of the outer surface of the valve housing 160 and the end of the housing
114 has a
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depression 208 for receiving an anti-rotation tab 210. An externally threaded
disc 212 and o-
ring 214 is secured in an internally threaded opening in the end of the
housing 114. The cut-
off screw 202 on the valve shaft 164 rotatably extends through a central hole
in the disc 212
and is held in place by the disc. As seen in FIGs. 5-7, a circumferential
groove 216 is
provided in the housing 114. With the valve assembly 120 in place, the groove
216 is
disposed between the o-rings 182 for forming a fluid path around the periphery
of the valve
housing 160 defined by the periphery of the valve housing between the o-rings
182 and the
inner surface of the housing 114 defining the groove 216.
[0083] As seen in FIG. 6, the housing 114 is provided with a passage 218
through
which fluid is transferred during reciprocal movement of the piston 116 in the
chamber for
regulating movement of the door 82. The fluid passage 218 runs longitudinally
between a
radial passage 220 in the housing 114 opening into the end of the housing 114
adjacent the
valve assembly 120 to a radial passage 222 in the housing 114 opening into the
chamber
adjacent the spring assembly 118. The passage 218 thus serves as a conduit for
fluid to pass
between the first variable volume chamber 148 on one side of the piston 116
and the second
variable volume chamber 150 on the other side of the piston 116.
[0084] When the door 82 is in the fully closed position, the components of
the door
closer 90 according to the present invention are as shown in FIG. 5. As the
door 82 is
opened, the door rotates the pinion 112 and thereby advances the piston 116
linearly to the
right as seen in FIGs. 6 and 7. Movement of the piston 116, in turn,
compresses the springs
138 between the piston 116 and the end plug 142. It is understood that the
door closer
assembly 80 can be used on a left hand door or a right hand door and,
therefore, the door
could be opened in a either a clockwise or a counterclockwise direction.
[0085] As the piston 116 moves toward the right end of the chamber in the
housing
114, the fluid surrounding the springs 138 is forced through the radial
passage 222 and into
the longitudinal fluid passage 218. The fluid passes through the radial
passage 220 at the end
of the housing 114 adjacent the valve assembly 120 and into the groove 216 in
the housing
114. Fluid thus surrounds the central portion of the valve housing 160 between
the o-rings
182 such that the opposed radial bores 184, 188 in the valve housing 160 are
in fluid
communication with the main fluid passage 218 through the housing 114 (FIG.
6). The fluid
flows into the radial passages 184, 188 in the valve housing 160 and the
through the
corresponding openings 194 in the valve sleeve 162 toward the valve shaft 164.
If the valve
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shaft 164 is in a closed position (FIG. 13), the fluid cannot advance because
the valve shaft
164 covers the openings to the other radial passages. If the valve shaft 164
is rotated to an
open position, such that a flow path exists between the radial passages as
shown in FIG. 14,
the fluid can flow to the radial passages 186, 190 in the valve housing 160
and to the axial
passages 174, 176 which open into the first variable volume chamber 148.
[0086] The degree of rotation of the valve shaft 164 relative to the valve
sleeve 162
regulates the rate of fluid flow past the valve shaft 164 and, thus, the speed
of movement of
the opening door 82. As shown in FIGs. 8 and 13C, a small portion of material
is removed
adjacent each groove 204, 205 on the valve shaft 164, forming partial
circumferential slots
224, 226 of increasing depth. The slots 224, 226 are positioned such that the
valve shaft 124
must rotate about seven degrees before the vertex of each slot 224, 226
intersects the
corresponding radial exit passages 194 in the valve sleeve 162. However, there
may be some
leakage around the valve shaft 164 causes some fluid transfer before the valve
shaft 164
rotates the full seven degrees and begins to uncover the passages 194. The
full length of the
slots 224, 226 from vertex to end may account for about fifteen degrees of
rotation of the
valve shaft 164 relative to the valve sleeve 162.
[0087] The slots 224, 226 function to provide more resolution in
controlling door
movement. Moreover, as fluid temperature increases, full movement of the door
82 may be
accomplished while the valve shaft 164 rotates only within the range provided
by the slots
224, 226. It is understood that, as the temperature of the fluid decreases,
the valve shaft 164
may be required to open further for providing a larger area for fluid flow for
equivalent fluid
transfer.
[0088] Referring to FIGs. 5 and 5A, another path through the piston 116 is
provided
for moving fluid from the second variable volume chamber 150 to the first
variable volume
chamber 148 during door 82 opening. As the piston 116 moves to the right away
from the
valve assembly 120 and fluid enters the first variable volume chamber 148, the
ball of the
check ball assembly 152 in the end of the piston 116 unseats and fluid is
forced around the
closed end of the piston 116, through the opening defined by the check ball
assembly 152 and
into the first variable volume chamber 148. Fluid flows freely until the
closed end of the
piston 116 passes the end of the groove 156. Because the end of the piston 116
adjacent the
second variable volume chamber 150 is closed and sealed relative to the inside
wall of the
housing 114, flow of fluid bypassing the piston 116 stops. This may occur, for
example,
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where the door 82 reaches a back check region or position, as described
herein. In general,
providing for fluid flow past the piston 116 allows a smooth transition when
the door initially
begins to move to an open position from a stop, or when the door is moving in
a closing
direction and there is a sudden change to moving in the opening direction.
Less power is
required to change the position of the valve shaft 164 under these conditions.
[0089] When the door 82 reaches a fully open position, the piston 116 is
in the
position shown in FIG. 7 and the springs 89 are compressed.
[0090] Movement of the door 82 from an open position to the closed
position is
effected by expansion of the springs 138 acting to move the piston 116 to the
left as seen in
FIGs. 5-7. The advancing piston 116 causes the pinion 112 to rotate for moving
the door 82
toward the closed position. Fluid pressure in the first variable volume
chamber 148 created
by the piston 116 moving toward the valve assembly 120 forces the ball in the
ball check
assembly 152 against its seat preventing fluid flow through the piston 116.
Fluid is then
forced out of the first variable volume chamber 148 in the housing 114,
through the valve
assembly 120, and the housing passages 218, 220, 222 and into the second
variable volume
chamber 150 around the springs 138. Specifically, the fluid initially flows
into the axial
passages 174, 176 and then to the corresponding radial passages 186, 190 to
the valve shaft
164. If the valve shaft 164 is in the closed position (FIG. 13), the fluid
cannot advance. If
the valve shaft 164 is rotated to an open position, such as shown in FIG. 14,
the fluid exits via
the grooves 204, 205 and slots 224, 225 of the valve shaft 164, the radial
openings 194 in the
valve sleeve 162, and into the radial passages 184, 188 in the valve housing
160 toward the
housing passages 218, 220, 222. Fluid again surrounds the central portion of
the valve
housing 160 between the o-rings 182 and exits through the housing passage 220.
The degree
of rotation of the valve shaft 164 relative to the valve sleeve 162 will
affect the rate of fluid
flow past the valve shaft 164 and, thus, the speed of movement of the closing
door 82. When
the door 82 reaches the closed position, the components of the door closer 90
are again as
shown in FIG. 5.
[0091] In general, the fluid path in the arrangement described herein,
provides for a
balance of forces on the valve assembly 120. Specifically, fluid surrounds the
central portion
of the valve housing 160 between the o-rings 182 and passes into the valve
assembly 120 via
opposed radial bores 184, 188. The opposed grooves 204, 205 and slots 224, 226
provided
on the valve shaft 164 also function to balance fluid flow through the valve
and minimize
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side loading of the valve shaft 164, which would otherwise increase torque
necessary to
rotate the valve shaft 164.
[0092] As seen in FIG. 15, a radial vent passage 228 is provided in the
valve housing
160 and is arranged in fluid communication with the radial bore 198 in the
valve sleeve 162
which communicates with the axial vent passage 196. The openings to the vent
passages
178, 228 in the valve housing 160 are counter-bored for receiving check balls
230, 232. The
diameter of the balls 230, 232 are larger than a smaller outer diameter
portion of the passages
178, 228 for allowing only one-way fluid flow. This arrangement of fluid
passages serves as
a vent relief in high pressure situations. Specifically, during door opening,
if the pressure in
the fluid flow path becomes excessive, the fluid pressure may force the ball
232 into the
larger diameter portion of the axial passage 178 through the valve housing 160
so as to open
the passage allowing fluid flow through the passage 178. It is understood that
fluid pressure
forces the other ball 230 onto the smaller outer diameter of the corresponding
radial passage
228 in the valve housing 160. Fluid surrounding the valve shaft 164 can exit
outwardly via
the radial passage 198 in the valve sleeve 162 and the radial passage 228 in
the valve housing
160 and out the axial vent passage 178 in the valve housing 160 and into the
first variable
volume chamber 148 via a hole 234 in the spool plate 166 (FIG. 10). During
door closing, if
the pressure in the fluid flow path becomes excessive, the fluid pressure may
force the ball
230 into the larger diameter portion of the passage 228 so as to open the
passage allowing
fluid flow through the passage 228. It is understood that fluid pressure
forces the other ball
232 onto the smaller outer diameter of the corresponding passage 178. Fluid
surrounding the
valve shaft 164 will thus exit outwardly via the radial passage 198 in the
valve sleeve 162 and
will continue outwardly through the radial vent passage 228 to the fluid flow
path around the
valve housing 160 in the groove 216 in the housing 114 and exits via the
housing passages
218, 220, 222. The pressure venting prevents a U-cup seal in the valve
assembly 120 from
energizing and causing a dynamic braking effect on the valve shaft 164. Thus,
it is
understood that the valve assembly 120 is balanced during operation by
surrounding the
valve housing 160 with fluid which flows via passages on opposite sides of the
valve housing
160.
[0093] According to an embodiment of the door closer assembly 80, the
position of
the valve shaft 164 may be dynamically changed during door movement for
controlling the
flow of fluid past the valve shaft 164 and through the passages. Thus, as the
door opens and
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closes, the valve position can be changed in order to provide varying levels
of hydraulic
resistance as a function of door angle. Fluid flow is controlled by powered
rotational
movement of the valve shaft 164, referred to herein as the "cut-off shaft (COS
164)". In this
regard, many conventional valves have a screw, referred to herein as the "cut-
off screw," that
is used to control the valve's "angular position." That is, as the cut-off
screw is rotated, the
valve's angular position is changed. The valve's "angular position" refers to
the state of the
valve setting that controls the fluid flow rate through the valve. For
example, for valves that
employ a cut-off screw to control flow rate, the valve's "angular position"
refers to the
position of the cut-off screw. In this regard, turning the cut-off screw in
one direction
increases the valve's angular position such that the valve allows a higher
flow rate through
the valve. Turning the cut-off screw in the opposite direction decreases the
valve's angular
position such that the fluid flow through the value is more restricted (i.e.,
the flow rate is
less). In one embodiment, the valve assembly 120 is conventional having a cut-
off screw 202
and the COS 164, or valve shaft, is coupled to or integral with the cut-off
screw 202 for
controlling fluid flow rate. Thus, rotation of the cut-off screw 202 changes
the angular
position of the valve shaft 164 and, therefore, affects the fluid flow rate.
[0094] The drive unit 100 is coupled to the cut-off screw 202 for rotating
the valve
shaft 164 as appropriate to control the angular position of the valve shaft
164 in a desired
manner, as will be described in more detail below. Referring to FIGs. 16 and
17, the drive
unit 100 comprises a COS 164 coupler 240, a motor coupler 242, a motor 244, a
mounting
bracket 246, a PCB board 252, and a cover, including a fixed cap 248 and a
rotating cap 250.
As shown in FIGs. 17 and 18, the COS 164 coupler 240 includes a disc 254 with
a hollow tab
extension 256 positioned at a center of the disc 254. The tab 256 defines a
hole 257 for
receiving the cut-off screw 202. The central axis of the hole 257 is aligned
with the central
axis of rotation of the disc 254. The inner wall of the tab 256 is dimensioned
such that the
cut-off screw 202 fits snugly into the tab 256 for fixed rotation of the cut-
off screw 202 and
the COS 164 coupler 240 (FIGs. 5-7).
[0095] Referring to FIGs. 20 and 21, the motor coupler 242 is also a disc
having a
hollow tab extension 258 positioned at a central axis of the motor coupler
242. The tab 258
defines an opening 259 for receiving a motor shaft 260, which is rotated by
the motor 244
under the direction and control of control logic as described herein. The
inner wall of the tab
258 defining the opening 259 is dimensioned such that the motor shaft 260 fits
snugly in the
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tab 258 for fixed rotation of the motor shaft 260 and the motor coupler 242.
The motor
coupler 242 has a second hollow tab extension 262 radially spaced from the
first hollow tab
extension 258. An axially extending pin 255 is disposed in the second hollow
tab extension
262. The inner wall of the tab 262 is dimensioned such that the pin 255 fits
snugly in the tab
262, and frictional forces generally keep the pin 255 stationary with respect
to the motor
coupler 242. Therefore, any rotation of the motor coupler 242 moves the pin
255 about the
center of the motor shaft 260. The motor coupler 242 has a third hollow tab
extension 264
radially spaced from the second hollow tab extension 262. A magnet 266 is
disposed in the
third hollow tab extension 264. For example, in one exemplary embodiment, the
magnet 266
is glued to the motor coupler 242, but other techniques of attaching the
magnet 266 to the
motor coupler 242 are possible in other embodiments. As the motor coupler 242
rotates with
the motor shaft 260, the pin 255 and the magnet 266 rotate about the central
axis of rotation
of the motor coupler 242.
[0096] Referring to FIGs. 18 and 22, the COS 164 coupler disc 254 has a
slot 268
which receives the pin 255 on the motor coupler 242. The slot 268 is
dimensioned such that
its width (in a direction perpendicular to the r-direction) is slightly larger
than the diameter of
the pin 255 so that frictional forces do not prevent the COS 164 coupler 240
from moving
relative to the pin 255 in the y-direction, which is parallel to the
centerline of the pin 255.
Therefore, if the COS 164 coupler 240 receives any mechanical forces in the y-
direction,
such as forces from a user kicking or slamming the door 82 or from pressure of
the fluid
flowing in the valve assembly 120, the COS 164 coupler 240 is allowed to move
in the y-
direction relative to the pin 255 thereby preventing such forces from passing
through the pin
255 to other components, such as the motor 244, coupled to the pin 255. Such a
feature can
help prevent damage to such other components and, in particular, the motor
244. In addition,
as shown by FIG. 22, the radial length of the slot 268 in the r-direction is
significantly greater
than the diameter of the pin 255 such that it is unnecessary for the alignment
between the
couplers 240, 242 to be precise. Indeed, any slight misalignment of the
couplers 240, 242
simply changes the position of the pin 255 along a radius of the COS 164
coupler 240
without creating stress between the pin 255 and the COS 164 coupler 240. That
is, slight
misalignments between the COS 164 coupler 240 and the motor coupler 242
changes the
location of the pin 255 in the r-direction. However, since the pin 255 can
move freely to at
least an extent in the r-direction relative to the COS 164 coupler 240, such
misalignments do
not create stress in either of the couplers 240, 242.
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[0097] In one exemplary embodiment, the width (perpendicular to the r-
direction) of
the slot 268 is about equal to or just slightly larger than the width of the
pin 255. Thus, the
width of the slot 268 is small enough so that any rotation of the motor
coupler 242 causes a
corresponding rotation of the COS 164 coupler 240, but is large enough so that
significant
friction or other mechanical forces are not induced by movement of the COS 164
coupler 240
in the y-direction. Allowing the COS 164 coupler 240 to move relative to the
motor coupler
242 in the y-direction not only prevents mechanical forces from transferring
from the COS
164 coupler 240 to the motor coupler 242, but also obviates the need to
precisely set the
separation distance between the couplers 240, 242.
[0098] The couplers 240, 242 can be made of various materials. In one
embodiment,
the couplers 240, 242 may be composed of plastic, which is typically a low
cost material. In
addition, the size of the couplers can be relatively small. Note that the
shapes of the couplers
240, 242, as well as the shapes of devices coupled to such components, can be
changed, if
desired. For example, the cross-sectional shape of the cut-off screw 202 may
be circular;
however, other shapes are possible. For example, the cross-sectional shape of
the cut-off
screw 202 could be a square or rectangle. In such an example, the shape of the
hole 257 in
the hollow tab extension 256 on the COS 164 coupler 240 may be a square or
rectangle to
correspond to the shape of the cut-off screw 202. In addition, the cross-
sectional shape of the
COS 164 coupler 240 is shown to be generally circular, but other shapes, such
as a square or
rectangle are possible. Similarly, the motor coupler 242 and the pin 255 may
have shapes
other than the ones shown explicitly in the FIGs.
[0099] In the embodiments described above, the pin 255 is described as
being fixedly
attached to the motor coupler 242 but not to the COS 164 coupler 240. In other
embodiments, other configurations are possible. For example, it is possible
for a pin 255 to
be fixedly coupled to the COS 164 coupler for rotation with the COS 164
coupler and thus
movable relative to a motor coupler.
[0100] In addition, it should be further noted that it is unnecessary for
the couplers
240, 242 to rotate over a full 360 degree range during operation. In one
exemplary
embodiment, about a thirty-five degree range of movement is sufficient for
providing a full
range of angular positions for the valve shaft 164 for opening and closing the
valve. In this
regard, assuming that the valve shaft 164 is in a fully closed position such
that the valve shaft
164 allows no fluid flow, then rotating the integral cut-off screw 202 about
35 degrees
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transitions the valve shaft 164 from the fully closed position to the fully
open position (i.e.,
the valve's flow rate is at a maximum for a given pressure). In such an
example, there is no
reason for the cut-off screw 202 to be rotated outside of such a 35 degree
range. However,
the foregoing 35 degree range is provided herein as merely an example of the
possible range
of angular movements for the valve shaft 164, and other ranges are possible in
other
embodiments. For example, as described herein, the slots 224, 226 allow a
range of angular
movement of about seven degrees, which may be sufficient as the temperature of
the fluid
increases.
[0101] The motor 244 (FIG. 20) is an electric reversible motor with a
portion of the
motor drive shaft 260 extending from the housing of the motor 244. The motor
244 is
reversible such that the rotation of the motor 244 in one direction will cause
the drive shaft
260 to rotate in one direction, and rotation of the motor 244 in the opposite
direction will
cause the drive shaft 260 to rotate in the opposite direction. Such motors are
widely
commercially available and the construction and operation of such motors are
well known;
therefore, the details of the motor 244 are not described in specific detail
herein. A suitable
motor 244 for use in the door closer assembly 80 of the present invention is a
3-volt motor
providing a gear ratio of 109:1 and a rated torque of 1.3 oz-in. The motor 244
operates under
the direction and control of the control unit 110, which is electrically
coupled to the motor via
an electrical cable, as will be described below.
[0102] The design of the couplers 240, 242 can facilitate assembly and
promote
interchangeability. In this regard, as described above, precise tolerances
between the cut-off
screw 202 and the motor shaft 260, as well as between couplers 240, 242, are
unnecessary.
For example, the couplers 240, 242 may be used to reliably interface motors
and door closers
of different vendors. Moreover, to interface the motor 244 with the door
closer 90, a user
simply attaches the COS 164 coupler 240 to the cut-off screw 202 and positions
the couplers
240, 242 such that the pin 255 on the motor coupler 242 is able to pass
through the slot 268 in
the COS 164 coupler 240 as the motor 244 is mounted on the door closer 90. As
described
above, there is no need to precisely align the couplers 240, 242 as long as
the couplers 240,
242 are appropriately positioned such that the pin 255 passes through the slot
268.
[0103] In this regard, slight misalignments of the couplers 240, 242 do
not create
significant stresses between the couplers 240, 242. For example, assume that
the couplers
240, 242 are slightly misaligned such that the centerline of the COS 164 does
not precisely
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coincide with the centerline of the motor shaft 260. That is, the central axis
of rotation of the
COS 164 coupler 240 is not precisely aligned with the center of rotation of
the motor coupler
242. In such an example, the pin 255 moves radially relative to the COS 164
coupler 240 as
the couplers 240, 242 rotate. In other words, the pin 255 moves toward or away
from the
central axis of rotation of the COS 164 coupler 240 as the couplers 240, 242
rotate. If the pin
255 is not movable along a radius of the COS 164 coupler 240 when the couplers
240, 242
are misaligned, then the rotation of the couplers 240, 242 would induce stress
in the couplers
240, 242 and pin 255. However, since the pin 255 is radially movable relative
to the COS
164 coupler 240 due to the dimensions of the slot 268, such stresses do not
occur.
[0104] In addition, as described above, the COS 164 coupler 240 is movable
in the y-
direction (i.e., toward and away from the motor coupler 242) without creating
stresses in the
couplers 240, 242 or transferring significant forces from the COS 164 coupler
240 to the
motor coupler 242. In this regard, the pin 255 is not fixedly attached to the
COS 164 coupler
240, and the length of the slot 268 in the r-direction (i.e., along a radius
of the COS 164
coupler 240) is sufficiently large so that the COS 164 coupler 240 can slide
along the pin 255
(or otherwise move relative to the pin 255) without transferring forces
through the pin 255 to
the motor coupler 242.
[0105] Referring to FIGs. 19 and 20, the PCB board 252 is positioned
between the
motor coupler 242 and the COS 164 coupler 240. In one exemplary embodiment,
the PCB
board 252 is attached to the mounting bracket 246 via, for example, screws 253
(FIG. 17), but
other techniques for mounting the PCB board 252 on the mounting bracket 246 or
other
component are possible in other embodiments.
[0106] As shown by FIGs. 16 and 17, the fixed cap 248 is coupled to the
mounting
bracket 246 with four screws. As shown by FIG. 24, the fixed cap 248 is
coupled to the
rotatable cap 250, which can be rotated relative to the fixed cap 248.
Referring to FIG. 23,
the rotatable cap 250 has a lip 278 that extends around a perimeter of the cap
250. The cap
250 has a plurality of notches 280 along such perimeter, but such notches 280
are
unnecessary in other embodiments. The interior of the fixed cap 248 defines a
channel 282
(FIG. 24) into which the lip 278 fits and through which the lip 278 slides. A
tab 284 extends
from the lip 278 and limits the movement of the rotatable cap 250 relative to
the fixed cap
248. In this regard, the fixed cap 248 has a pair of stops (not shown). The
cap 250 is
rotatable within the tab 284 between the stops. As the cap 250 is rotated in
one direction, the
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tab 284 eventually contacts one of the stops preventing further movement of
the cap 250 in
such direction. As the cap 250 is rotated in the opposite direction, the tab
284 eventually
contacts the other stop preventing further movement of the cap 250 in such
direction. In one
exemplary embodiment, the cap 250 is rotatable up to 180 degrees (i.e., half
of full
revolution). Limiting the movement of the cap 250 helps to prevent
entanglement of a motor
cable 288 within or passing through the cap 250.
[0107] Referring to FIG. 26, an embodiment of the motor cable 288 is shown
as a
flexible electrical cable and is electrically connected to the motor 244 and
the PCB board
252. The rotatable cap 250 has a receptacle 286 for passing the motor cable
288, such that
the motor cable 288 extends outwardly through the cover. The outer end of the
motor cable
288 terminates in a connector 290 that electrically connects the motor cable
288 to an
electrical cable from the control unit, as will described below. Thus, one end
of the motor
cable 288 is connected to the cable 292 from the control unit 110, and the
other end is
connected to the PCB board 252 thereby electrically connecting the drive unit
100 to the
control unit 110. It is possible to position the control unit 110 at various
locations, such as
either on top of or below the door closer, and to then rotate the cap 250
until the receptacle
286 is oriented in a manner conducive to receiving the motor cable 288. In
addition, the cap
250 may be rotated such that the receptacle 286 is generally faced downward in
order to help
keep rainwater from falling into the receptacle 286 and reaching electrical
components
housed by the covers 248, 250. Another embodiment of a cover 294 for the drive
unit 100 is
shown in FIG. 27. In this embodiment, a slot 295 centered in the end of the
cover 294 passes
the motor cable 288, which protrude through the center of the cap 294. The
covers 248, 250,
294 may be composed of plastic, but other materials for the covers are
possible in other
embodiments.
[0108] The motor 244 is secured to the mounting bracket 246 using screws
274 (FIG.
17) received in threaded openings in the bracket 246. The motor 224 has
opposed ears which
are received in corresponding tabs on the bracket 246 for securing the motor
244 against
rotation. A sealing ring 272 is received in a corresponding recess in the
mounting bracket
246 and for engaging the door closer housing 114. The mounting bracket 246 is
then
fastened to the door closer housing 114 using threaded fasteners received in
axial threaded
openings 270 in the comers of the end of the housing 114 (FIG. 3). Opposed
axial tabs 271
are received in corresponding openings at the other comers. The mounting
bracket 246 is
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then fastened to the door closer housing 114 using threaded fasteners received
in axial
threaded openings 270 in the corners of the end of the housing 114 (FIG. 3).
The cut-off
screw 202 passes through the opening of mounting bracket 246. The sealing ring
272 helps
to keep any water from seeping between the drive unit 100 and the door closer
90 and
reaching the various electrical components of the drive unit.
[0109] As shown by FIG. 25, two magnetic sensors 299a, 299b are mounted on
an
inner surface 298 of the PCB board 252. The magnetic sensors 299a, 299b are
configured to
detect the strength of the magnetic field generated by the magnet 266 on the
motor coupler
242. Such a detection is indicative of the angular position of the valve shaft
164 of the door
closer 90. As described herein, to change such angular position, the motor 244
rotates the
motor shaft 260 causing the motor coupler 242 to rotate so that the motor
coupler 242 moves
the pin 255 about the motor shaft 260. Such rotation is translated to the COS
164 coupler
240 through the pin 255
[0110] When moving, the pin 255 presses against and moves the COS 164
coupler
240. In particular, the pin 255 rotates the COS 164 coupler 240 and,
therefore, the cut-off
screw 202 that is inserted into the hollow tab extension 256. The rotation of
the cut-off screw
202 changes the angular position of the valve shaft 164. Since rotation of the
motor coupler
242 ultimately changes the angular position of the valve shaft 164, the
position of the magnet
266 relative to the sensors 299a, 299b on the PCB board 252, which is
stationary, indicates
the angular position of the valve shaft 164.
[0111] The sensors 299a, 299b are configured to transmit a signal having a
voltage
that is a function of the magnetic field strength sensed by both of the
sensors 299a, 299b. In
one exemplary embodiment, the sensors 299a, 299b are ratiometric sensors such
that a ratio
(R) of the input voltage to the sensors to the output voltage to the sensors
is indicative of the
angular position of the valve shaft 164. In this regard, each discrete angular
position of the
valve shaft 164 is associated with a specific voltage ratio (R), which is
equal to the input
voltage of the sensor 299a, 299b divided by the output voltage of the sensor
299a, 299b. For
example, assume that to open the valve shaft 164 more so that flow rate
increases, the motor
coupler 242 is rotated such that the magnet 266 is moved closer to one of the
sensors 299a
thereby increasing the magnetic field strength sensed by the sensor 299a. In
such an
example, R increases the more that the valve shaft 164 is opened. Further, R
decreases when
the motor coupler 242 is rotated such that the magnet 266 is moved away from
the sensor
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299a. Thus, R decreases as the valve shaft 164 is closed in order to decrease
flow rate. It
also follows that the further away from the ratiometric sensor 299a that the
magnet 266 gets,
the lower the reading R and therefore causing an eventual unknown position of
the valve
shaft 164. To prevent this as well as allowing for a longer distance of
angular travel for the
valve shaft 164, the other ratiometric sensor 299b can simultaneously read
positions as the
first ratiometric sensor 299a readings of R go out of range. The other
ratiometric sensor 299b
then controls within the new range using the same methodology as described
above. The
only difference being that as the readings from the first ratiometric sensor
299a get weaker,
the other ratiometric sensor 299b will be in a better physical proximity to
assume control.
[0112] In one exemplary embodiment, control logic stores data, referred to
herein as
"valve position data," that maps various possible R values to their
corresponding angular
positions for the valve shaft 164. Thus, the control logic can determine an R
value from a
reading of the sensors 299a, 299b and use the stored data to map the R value
to the angular
position of the valve shaft 164 at the time of the reading. In other words,
based on the
reading from the sensors 299a, 299b and the mappings stored in the valve
position data, the
control logic can determine the angular position of the valve shaft 164.
[0113] Note that the use of a ratiometric sensor can be desirable in
embodiments for
which power is supplied exclusively by a generator. In such an embodiment,
conserving
power can be an important design consideration, and it may be desirable to
allow the input
voltage of the sensors 299a, 299b to fluctuate depending on power demands and
availability.
Using a voltage ratio to sense valve position allows the input voltage to
fluctuate without
impairing the integrity of the sensor readings. In other embodiments, other
types of magnetic
sensors may be used to sense the magnetic field generated by the magnet 266.
[0114] In one exemplary embodiment, the electrical cables 288, 292
comprise at least
six wires. In this embodiment, the sensors 299a, 299b may be coupled to the
control unit 110
via six wires of the cables 288, 292. Two wires carry an input voltage for the
sensors 299a,
299b circuitry. Two other wires carry an output voltage for the sensors 299a,
299b, and the
fifth and sixth wires carry an enable signal for each sensor. In this regard,
each sensor 299a,
299b is configured to draw current from the control logic only when receiving
an enable
signal from the logic. Thus, if the sensors 299a, 299b do not receive an
enable signal, the
sensors 299a, 299b do not usurp any electrical power. Moreover, when the
control logic
desires to determine the current position of the valve shaft 164, the control
logic first
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transmits an enable signal to one of the sensors 299a, 299b that should be
activated based
upon a temperature profile or table, waits a predetermined amount of time
(e.g., a few
microseconds) to ensure that the sensor 299a, 299b is enabled and providing a
reliable
reading, reads a sample from the one of the sensors 299a, 299b and then
disables the sensor
thereby preventing the sensor from drawing further current. Accordingly, for
each reading,
each sensor 299a, 299b draws current only for a short amount of time thereby
helping to
conserve electrical power.
[0115] In one exemplary embodiment, readings from the sensors 299a, 299b
are used
to assist in the control of the motor 244. In such an embodiment, the control
logic instructs
the motor 244 when and to what extent to rotate the motor shaft 260 (thereby
ultimately
rotating the cut-off screw 202 by a corresponding amount) by transmitting
pulse width
modulation (PWM) signals to the motor 244 via electrical cable. In this
regard, pulse width
modulation is a known technique for controlling motors and other devices by
modulating the
duty cycle of control signals. Such techniques can be used to control the
motor 244 such that
the motor 244 drives the motor shaft 260 by an appropriate amount in order to
precisely
rotate the motor shaft 260 by a desired angle.
[0116] In controlling the door closer 90, the control logic may determine
that it is
desirable to set the angular position of the valve shaft 164 to a desired
setting. For example,
the control logic may determine that the angle of the door 82 has reached a
point at which the
force generated by the door closer 90 is to be changed by adjusting the
angular position of the
valve shaft 164. If the current angular position of the valve shaft 164 is
unknown, the control
logic initially determines such angular position by taking a reading of the
sensors 299a, 299b
in the drive unit 100. In this regard, the control logic enables the sensors
299a, 299b based
on the temperature table, waits a predetermined amount of time to ensure that
the sensors are
enabled and is providing a reliable value, and then determines the angular
position of the
valve shaft 164 based on the sensor reading. In one exemplary embodiment in
which the
sensors 299a, 299b are ratiometric, the control logic determines the ratio, R,
of the input
voltage to the sensor and the output voltage form the sensor and maps this
ratio to a value
indicative of the current angular position of the valve shaft 164 via the
valve position data.
[0117] Based on the current angular position of the valve shaft 164, the
control logic
determines to what extent the cut-off screw 202 is to be rotated in order to
transition the valve
shaft 164 to the desired angular position. For example, the control logic can
subtract the
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desired angular position from the current angular position to determine the
degree of angular
rotation that is required to transition the valve shaft 164 to the desired
angular position. The
control logic then transmits a PWM signal to the motor 244 to cause the motor
to rotate the
motor shaft 266 by a sufficient amount in order to transition the valve shaft
164 to its desired
angular position. In response, the motor 244 rotates the shaft 266 thereby
rotating the motor
coupler 242. Since the pin 255 passes through the COS 164 coupler 240, the COS
164
coupler 240 rotates in unison with the motor coupler 242 thereby rotating the
cut-off screw
202. Accordingly, the motor 244 effectively drives the cut-off screw 202 such
that the valve
shaft 164 is transitioned to its desired angular position. Once the valve
shaft 164 is
transitioned to its desired angular position, the control logic, if desired,
can take another
reading of the sensors 299a, 299b, according to the techniques described
above, in order to
ensure that the valve shaft 164 has been appropriately set to its desired
angular position. If
there has been any undershoot or overshoot of the angular position of the
valve shaft 164, the
control logic can transmit another PWM signal to the motor 244 in order to
activate the motor
244 to correct for the undershoot or overshoot.
[0118] FIGs. 28 and 29 depict an exemplary embodiment of the control unit
110. The
control unit 110 may also be referred to herein as a "controller". The
components of the
control unit 110 are housed by a two-piece cover 303a, 303b, which can be
mounted on the
bottom or the top of the door closer 90.
[0119] As described above, the control unit 110 has a printed circuit
board (PCB) 300
on which logic, referred to herein as the "control logic," resides. Such logic
may be
implemented in hardware, software, firmware, or any combination thereof. In an
exemplary
embodiment illustrated in FIG. 30, the control logic 580 is implemented in
software and
stored in memory 582 mounted on the PCB 300.
[0120] The exemplary embodiment of the PCB 300 depicted by Fig. 30
comprises at
least one processing element 585, such as a digital signal processor (DSP) or
a central
processing unit (CPU), that communicates to and drives the other elements of
the PCB 300
via a local interface 588, which can include at least one bus. Furthermore, an
electrical
interface 589 can be used to exchange electrical signals, such as power or
data signals, with
other components in the door closer assembly 80 or external to the door closer
assembly 80.
In one exemplary embodiment, the electrical cable 292 of the control unit 110
is coupled to
the interface 589.
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[0121] Note that Fig. 30 also shows a workstation 1000 optionally
connected to the
electrical interface 589. This workstation may serve as an instruction
execution platform to
execute software 1002 stored on a storage medium 1004 that runs during a
calibration mode
to store calibration positional values in memory 582. The calibration mode is
discussed in
detail later with respect to FIGs. 47 and 48. In some embodiments the
calibration software
may be in the workstation. In other embodiments, it may be stored in memory
582. In still
other embodiments, it may reside in part or in whole in both places. The
software may be
distributed as part of a computer program product including computer program
code or
instructions on a medium or on media. The memory may be any of various types.
In some
embodiments, an EEPROM can be used.
[0122] Any suitable computer usable or computer readable medium may be
utilized.
The computer usable or computer readable medium may be, for example but not
limited to,
an electronic, magnetic, optical, or semiconductor system, apparatus, or
device. More
specific examples (a non-exhaustive list) of the computer readable medium
would include
any tangible medium such as a portable computer diskette, a hard disk, a
random access
memory (RAM), a read-only memory (ROM), an erasable programmable read-only
memory
(EPROM, EEPROM or flash memory), a compact disc read-only memory (CD-ROM), or
other optical, semiconductor, or magnetic storage device
[0123] The components of the PCB 300 receive electrical power from a
generator,
which will be described in more detail below. It should be noted that there
are varied
methods of harnessing door movement energy as well as translating the physical
movement
into electrical energy, but due to the modular design of this exemplary
embodiment of a door
closer assembly 80, differing implementations can be used when appropriate.
One method
explained in detail will be referred to as the direct drive method throughout
this document.
[0124] Referring now to FIGs. 29 and 31, a large drive gear 302 is
rotatably mounted
on a base plate 304 using an S-shaped bracket. The base plate 304 is supported
on four
internally threaded posts 305a and held in place with screws 305b threaded
into the posts
305a. The drive gear 302 defines a star-shaped opening 306 for receiving an
end of the
pinion 112 of the door closer 90. The end of the pinion 112, which is square,
fits in the
opening 306 such that the large drive gear 302 is rotated with the pinion 112
during door 82
movement. The large drive gear 302 is the start of all direct drive method
power generation.
The drive gear 302 engages a chain 308. Linear motion of the chain 308 in
either the +/- x
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direction results in corresponding clockwise/counterclockwise rotation of a
small drive
sprocket 310 longitudinally spaced from the drive gear 302 on the base plate
304. An idler
tension gear 311 on the base plate 304 is adjustable for holding the chain 308
at the
appropriate tension to allow for all gear teeth to grip the chain 308 during
door 82 motion.
[0125] The direct drive method harnesses the rotational motion from the
pinion 112
of the door closer 90, which is coupled to the large drive gear 302. When the
pinion 112
rotates through door movement, such rotational motion is translated into
linear motion down
the chain 308 in the +/- x direction depending on clockwise or
counterclockwise rotation of
the pinion 112. For example, if rotation of the pinion 112 is in the clockwise
direction, and
the linear motion of the chain 308 is in the -x direction, it also follows
that counter-clockwise
rotation of the pinion 112 will propagate the chain 308 in the +x direction.
It should be noted
that rotational motion of the pinion 112 in either the clockwise or
counterclockwise direction
is the result of the door 82 being opened or closed and will vary in eventual
linear +/- x
motion depending on orientation of mounting of the door closer assembly 80.
[0126] Referring to FIGs. 32 and 33, the drive sprocket 310 is fixed for
rotation with
a large compound box gear 312 on the opposite side of the base plate 304
through a sprocket
shaft 313. The box gear 312 has a larger diameter than the drive sprocket 310,
thereby
maintaining the rotational rate of the original door 82 motion. The box gear
312 also has a
higher tooth density, which helps distribute the angular rotational torque, so
varying materials
can be used in the box gear design. This arrangement also helps prevent the
box gear 312
from exerting a reverse torque and thereby inhibiting the door from opening or
closing freely.
[0127] Since the pinion 112 and the large box gear 312 will rotate in the
same
clockwise or a counterclockwise direction depending on the direction the door
82 is moving,
a pair of clutch gears 314a, 314b are provided. The clutch gears 314a, 314b
ensure that,
regardless of the direction of rotation of the box gear 312, all downstream
gear rotation,
including the final interpretation of a generator gear 330, is the same
direction of rotation.
Thus, electrical energy will be generated in the same manner regardless of the
direction the
door 82 is moving. The set of clutch gears 314a, 314b also ensures that the
gears further
downstream will not be subject to unwanted gear wear associated with bi-
directional rotation.
It should be noted that a regulated generator is an alternative design for
this exemplary
embodiment, which would render the pair of clutch gears unnecessary.
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[0128] The gear train for achieving unidirectional rotation of the
generator gear 330 is
shown in FIGs. 32-37. The clutch gears 314a, 314b are disposed on a shaft 315
extending
between the base plate 304 and a support plate 320 secured to posts extending
from the base
plate 304 such that the support plate 320 is spaced from and parallel to the
base plate 304.
Rotational motion from the box gear 312 is directly transferred to the inner
clutch gear 314b
by direct engagement with the larger gear 316 of the box gear 312. The
opposite rotational
motion is simultaneously transferred from the box gear 312 through an
intermediary gear
318. The intermediary gear 318 spins freely on a shaft 319 extending between
the base plate
304 and the support plate 320 by direct engagement with smaller gear 317 of
the box gear
312. The intermediary gear 318 directly engages the outer clutch gear 314a.
The clutch
gears 314a, 314b are oriented such that the clutch gears 314a, 314b only grip
the shaft 319 for
rotation in one direction. For example, when the box gear 312 rotates
clockwise, the outer
clutch gear 314a grips the shaft 315 through the intermediary gear 318 and
turns the shaft 315
in the clockwise direction. The inner clutch gear 314a spins freely in the
counterclockwise
direction. It also follows that when the box gear 312 rotates in the
counterclockwise
direction, the inner clutch gear 314b directly grips the shaft 315 and rotates
the shaft 315 in
the clockwise direction while the outer clutch gear 314a spins freely in the
counterclockwise
direction through the intermediary gear 318. In this manner, the shaft 315
only receives one
direction of rotation, which is transferred to a fixed drive gear 322 non-
rotatably disposed on
the shaft 315 on the other side of the base plate 304. Thus, a single
direction of rotation is
established for all gears between the generator gear 330 and the clutch gears
314a, 314b. It
follows that, since the door 82 opening or closing motion can be translated
into unidirectional
rotation on the fixed drive gear 322, all subsequent gears will only see one
direction of
rotation regardless of whether the door 82 is opening or closing.
[0129] The fixed drive gear 322 transfers rotational motion through a
series of
compound gears 324, 326, 328, 330 with the explicit intent to increase overall
rotational
velocity for any given motion of the pinion 112, which is directly derived
from door 82
movement. The fixed drive gear 322 engages the smaller inner gear of the
compound gear
324 rotatably mounted on an adjacent shaft 332. The larger gear of the
compound gear 324
engages the smaller gear of the compound gear 326 rotatably mounted on the
clutch gear
shaft 315. The larger gear of the compound gear 326 engages the smaller gear
of the third,
large compound gear 328 which is also on the adjacent shaft 332. This final
higher velocity
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rotation of the large compound gear 328 is transferred to the generator gear
330 affixed to a
generator 334.
[0130] For the embodiment as depicted, the rotational energy derived from
door
opening or closing and redirected through the subsequent gear train described
above is used
by the generator 334 to generate electrical power. The large drive gear 302
advances the
chain 308 by door movement in the opening or closing direction, and the
generator 334
generates power when the door is moving. The generator supplies power through
connected
wires, which may be part of a multi-conductor cable, such as cable 292. When
the door 82 is
no longer moving, such as after the door fully closes, various electrical
components, such as
components on the PCB 300, are shut-off. Thus, the electrical power
requirements of the
door closer assembly 80 can be derived solely from movement of the door, if
desired. Once a
user begins opening the door, the movement of the door 82 directly drives the
large drive
gear 302 and subsequently the gear train to the generator 334 and electrical
power is,
therefore, generated. When the generator 334 begins providing electrical
power, the
electrical components are powered, and the door closer assembly 80 is
controlled in a desired
manner until the door closes or otherwise stops moving at which time various
electrical
components are again shut-off.
[0131] It should be emphasized that techniques described above for
generating
electrical power are exemplary. Other techniques for providing electrical
power are possible
in other embodiments, and it is unnecessary for electrical components to be
shut-off in other
embodiments. In addition, other devices besides a generator can be used to
provide power
for the controller 110. For example, it is possible for the control unit 110
to have a battery
(not shown) in addition, or in lieu of, the generator 334 in order to provide
power to the
electrical components of the door closer assembly 80. In such a case, the
device to provide
power consists of a battery holder with connections for the control circuitry.
However, a
battery, over time, must be replaced. The device to provide power might also
be a connector
or wires to interface with external power. In one exemplary embodiment, the
control unit
110 is designed such that all of the electrical power used by the control unit
110 is generated
by the generator 334 so that use of a battery is unnecessary. In other
embodiments, electrical
power can be received from other types of power sources.
[0132] As described above, the control logic 580 may function to adjust
the angular
position of the valve shaft 164 based on the door angle. There are various
techniques that
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may be used to sense door angle. In one exemplary embodiment, the control
logic 580 is
configured to sense the door angle based on a magnetic position sensor,
similar to the
techniques described above for sensing the angular position of the valve shaft
164 via the
magnetic sensors 299a, 299b in the drive unit 100.
[0133] Referring to FIGs. 38-40, the control unit 110 comprises an arcuate
arm gear
336 that is coupled to the pinion 112 through the drive gear 302 and arm
encoder gears 331a,
331b. The arm encoder gears 331a, 331b are fixed for joint rotation on a post
338 extending
from the base plate 304 at a position longitudinally spaced from the drive
gear 302. The
smaller upper encoder gear 321b is engaged with the arm gear 336. As best seen
in FIG. 40,
the drive gear 302 has a smaller inner gear that engages the larger arm
encoder gear 331a.
When the large drive gear 302 rotates with the pinion 112, the lower arm
encoder gear 331a
also rotates by engagement with a smaller inner gear 362 on the drive gear
302. Since the
upper arm encoder gear 331b rotates with the lower arm encoder gear 331a,
interaction of the
upper arm encoder gear 331b and the arm gear 336 rotates the arm gear 336.
Thus, any
rotation of the pinion 112 caused by movement of the door 82 causes a
corresponding
rotation of the arm gear 336. In one embodiment, the pinion 112 rotates at a
ratio of six-to-
one relative to the arm gear 336. That is, for six degrees of rotation of the
pinion 112, the
arm gear 336 rotates one degree. However, other ratios are possible in other
embodiments.
[0134] At least one magnet 340 is mounted on the arm gear 336. The PCB 300
is
mounted over the arm gear 336 on four threaded posts with screws. At least one
magnetic
sensor 342 is mounted on the PCB 300. The magnetic sensor 342 is stationary,
and the
magnet 340 moves with the arm gear 336. Thus, any movement by the door 82
causes a
corresponding movement by the magnet 340 relative to the sensor 342. The
control logic 580
is configured to determine a value indicative of the magnetic field strength
sensed by the
sensor 342 and to then map such value to the angular position of the door 82.
Further, as
described above, the control logic 580 is configured to use the angular
position of the door 82
to control the angular position of the valve shaft 164, thereby controlling
the force generated
by the door closer 90.
[0135] For illustrative purposes, assume that it is desirable for the door
closer 90 to
control the hydraulic force generated by the closer during opening based on
two door angles,
referred to hereafter as "threshold angles," of fifty degrees and seventy
degrees. In this
regard, assume that the door closer is to generate a first hydraulic force
resistive of the door
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motion during opening for door angles less than fifty degrees. Between fifty
and seventy
degrees, the door closer is to provide a greater hydraulic force resistive of
the door motion.
For door angles greater than seventy degrees, the door closer is to provide a
yet greater
hydraulic force resistive of the door motion. This high-force region of motion
is often termed
the "back check" region, since the greater force is intended to prevent the
back of the door
from hitting a wall or stop. Further assume that during closing, the closer is
to generate
another hydraulic force for door angles greater than fifteen degrees and a
smaller hydraulic
force for door angles equal to or less than fifteen degrees. This latter
region, where the door
is close to the jamb, is often referred to as the "latch region" of motion.
These angles are a
design choice and can vary.
[0136] As shown by FIG. 30, the control logic 580 stores threshold data
590
indicating the desired opening and closing characteristics for the door 82. In
this regard, the
data 590 indicates the threshold angles and the desired angular position of
the valve for each
threshold range. In particular, the data 590 indicates that the angular
position of the valve is
to be at one position, referred to hereafter as the "high-flow position," when
the door angle is
fifty degrees or less during opening, but the door is not in the latch region.
The data 590 also
indicates that the angular position of the valve to be at another position,
referred to hereafter
as the "medium-flow position," when the door angle is greater than fifty
degrees but less than
or equal to seventy degrees during opening. The data 590 further indicates
that the angular
position of the valve is to be at yet another position, referred to hereafter
as the "low-flow
position," when the door angle is greater than seventy degrees during opening,
and thus the
door is in the back-check region. Note that the medium-flow position allows a
lower flow
rate than that allowed by the high-flow position, and the low-flow position
allows a lower
flow rate than that allowed by the medium-flow position, and also that there
may be many
variations of angle used as trigger points for entering into a particular flow
rate region as well
as numerous degrees of each flow rate described above. Thus, the hydraulic
forces generated
by the closer resisting door movement should be at the highest above a door
angle of 70
degrees and at the lowest below a door angle of 50 degrees. In addition,
assume that the data
590 also indicates that, when the door is closing, the angular position of the
valve is to be at a
position for angles less than or equal to 15 degrees to allow for very slow
closing in the latch
region.
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[0137] In some embodiments of the closer assembly, velocity measurements
of door
movement can add more intelligence to COS 164 movement decisions. Deciding if
a
threshold has been met is only one scenario of trying to mitigate an
unnecessary reposition of
the COS 164. It also follows that if door movement is slow enough during
opening mode that
there will not be a need to move the COS 164 to the next mode of COS, valve
operation
stored in the threshold data 590. For instance, if when opening the door 82
under normal
decision processing, the threshold data 590 determines that the door movement
requires the
COS 164 be positioned at a low flow rate to prevent the door from opening
further than
desired, it then will have to perform another movement to position the COS 164
in the
appropriate position for a close mode when the threshold data 590 has
determined it is
necessary. So, in this embodiment, the COS 164 had to make two movements and
therefore
use energy for moving the COS 164 both times. However, if after determining
the door 82 is
closing the determination was made whether there was a predetermined high
velocity
violation, the decision for determining if the COS 164 should be moved to the
next position
would only happen if velocity is too high. This will help conserve energy
during slow door
movement, which does not require a low-flow rate to protect the door from
opening too fast
and therefore allow the closer to bypass one movement of the COS 164 as normal
operation
would indicate. A process that can be used to measure the velocity of the door
is to determine
the door angle difference over time using a timer in the control logic 580.
Furthermore, it
also follows that this same velocity measurement can be used to make other
decisions that the
control logic 580 will discern. For example, if the velocity is extremely
high, a decision
could be made to move COS 164 to a low flow rate position sooner than
threshold data 590
normally requires. This would be useful in a scenario where a door 82 is being
kicked and
thereby prevent damage to people or the surroundings.
[0138] As described above, electrical power can be harnessed from the
energy created
by door movement. In one exemplary embodiment, all of the electrical power for
powering
the electrical components of the door closer 90, including electro-mechanical
components,
such as the motor 244, is derived from door movement. Accordingly, the door
closer
assembly 80 may not be provided with power from an external power source and
does not
require batteries. Since power is limited and only available when the door 82
is moving and a
short time thereafter, various techniques are employed in an effort to
conserve power to help
ensure that there is enough power to control valve position in a desired
manner.
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[0139] In one embodiment, the sensors 299a, 299b in the drive unit 100
and the
sensor 342 in the control unit 110 are enabled only for enough time to ensure
that an accurate
reading is taken. In this regard, the control logic 580 enables the sensors
299a, 299b, waits a
short amount of time (e.g., a few microseconds), takes a reading, and then
disables the
sensors 299a, 299b. Indeed, in one embodiment, the control logic 580 enables
the one of the
sensors 299a, 299b in the drive unit 100 in response to a determination that a
reading of the
sensor 299a, 299b should be taken, and the control logic 580 thereafter
disables the sensors
299a, 299b in response to the occurrence of the reading. Thus, for each
reading, the sensor
299a, 299b draws power for only a short time period, such as about 10
microseconds.
Similarly, the control logic 580 enables the sensor 342, waits a short amount
of time (e.g., a
few microseconds), takes a reading, and then disables the sensor 342. Thus,
for each reading,
the sensor 342 draws power for only a short time period, such as about 10
microseconds.
Note that, as described above for the drive unit sensors 299a, 299b, the
sensor 342 on the
POCB 300 may be enabled in response to a determination that a reading of the
sensor 342
should be taken and may be disabled in response to a determination that such
reading has
occurred.
[0140] To further help conserve power, the control logic 580 tracks the
amount of
power that is available and takes various actions based on the amount of
available power, as
will be described in more detail below. In one embodiment, FIG. 41 depicts an
exemplary
circuit for providing power to various electrical components of the door
closer assembly 80.
In this regard, a power management circuit 525 is coupled to the generator 334
via a diode
527. As described herein, when the large drive gear 302 in the control unit
110 is rotated by
door movement, and the chain 308 transfers the motion through the gear train,
the generator
334 generates an electrical pulse. As long as the door continues moving, the
generator 334
repetitively generates electrical pulses.
[0141] Each electrical pulse from the generator 334 charges the power
management
circuit 525. The power management circuit 525 is comprised of a charge pump
525a,
SuperCapTM battery ("SuperCap") 525b, and an electrolytic capacitor 525c,
which are
electrically combined to maximize instant voltage output for low power
situations and to
maximize energy storage when power is being generated. In general, as power is
generated
by the generator 334, a circuit detects if the voltage being generated is
greater than zero volts
but less than 5 volts, and if so will turn on the charge pump 525a to double
the voltage. This
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type of circuit can help minimize the errors that a slow moving door can cause
when not
enough power is available to move the COS 164 to the appropriate position. For
example, in
this exemplary embodiment, a slow moving door may provide one to two volts on
the onset
of the slow movement and therefore not generate enough energy for control
circuitry 540 to
determine if a valve movement needs to take place, but with the charge pump
the control
circuitry 540 would wake immediately and determine next course of action
without delay and
therefore be able to move the COS 164 when appropriate.
[0142] However, once the voltage level increases past five volts from the
generator
334, the efficiencies of the charge pump 525a start to reduce and may damage
the rest of the
circuit, so the circuit then switches the outputted voltage away from the
charge pump 525a
and directly charges the electrolytic capacitor 525c until such time the
voltage being
generated then rises above 6 volts, which then means the energy being produced
is more than
required for immediate use, so it can be stored. Upon determining extra
voltage is available
the circuit then allows the outputted energy to charge the carbon SuperCap
525b and the
electrolytic capacitor 525c simultaneously so that all energy being generated
is available for
valve operation or being stored for later use. Since the electrolytic
capacitor 525b is of much
smaller capacitance, its charging and discharging properties are relatively
fast and respond to
COS 164 movement needs instantaneously. The carbon SuperCap 525b has a much
higher
capacitance and is used to recharge the electrolytic capacitor when no power
is being
generated but energy is still needed for valve operation.
[0143] Accordingly, if the door is moving fast enough, electrical power is
continually
delivered to control circuitry 540 during such movement. As shown by FIG. 41,
a voltage
regulator 545 is coupled to the capacitor 525c and regulates the output from
the power
management circuit 525, so that this voltage is constant provided that there
is sufficient
power available to maintain the constant voltage. For example, in one
embodiment, the
regulator 545 regulates the voltage across the power management circuit 525 to
three volts.
Thus, as long as the power management circuit 525 is sufficiently charged, the
regulator 545
keeps the voltage across capacitor 525c equal to three volts. However, if the
door stops
moving thereby stopping the generation of electrical pulses by the generator
334, then the
voltage across the power management circuit 525 eventually falls below three
volts as the
electrolytic capacitor 525c and carbon SuperCap 525b discharges.
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[0144] Also as shown by FIG. 41, the control circuitry 540 in one
exemplary
embodiment comprises a microprocessor 555. Further, in such embodiment, at
least a portion
of the control logic 580 is implemented in software and run on the
microprocessor 555 after
being loaded from memory. The microprocessor 555 also comprises a timer 563
that is
configured to generate an interrupt at certain times, as will be described in
more detail
hereafter.
[0145] The parameters on which decisions are made to adjust valve position
change
relatively slowly compared to the speed of a typical microprocessor. In this
regard, a typical
microprocessor is capable of detecting parameters that have a rate of change
on the order of a
few microseconds, and a much longer time period is likely to occur between
changes to the
state of the valve position. To help conserve power, the control logic 580 is
configured to
transition the microprocessor 555 to a sleep state after checking the sensors
299a, 299b, 342
and adjusting valve position based on such readings, if appropriate.
[0146] Before transitioning to the sleep state, the control logic 580
first sets the timer
563 such that the timer 563 expires a specified amount of time (e.g., 100
milliseconds) after
the transition to the sleep state, When the timer 563 expires, the timer 563
generates an
interrupt, which causes the microprocessor 555 to awaken from its sleep state.
Upon
awakening, the control logic 580 checks the sensors 299a, 299b, 342 and
adjusts the valve
position based on such readings, if appropriate. Thus, the microprocessor 555
repetitively
enters and exits a sleep state thereby saving electrical power while the
microprocessor 555 is
in a sleep state. Note that other components of the control circuitry 540 may
similarly
transition into and out of a sleep state, if desired.
[0147] In one exemplary embodiment, the control logic 580 monitors the
voltage
across the power management circuit 525 to determine when to perform an
orderly shut-
down of the control circuitry 540 and, in particular, the microprocessor 555.
In this regard,
the control logic 580 is configured to measure the voltage across the power
management
circuit 525 and to compare the measured voltage to a predefined threshold,
referred to
hereafter as the "shut-down threshold." In one embodiment, the shut-down
threshold is
established such that it is lower than the regulated voltage but within the
acceptable operating
voltage for the microprocessor. In this regard, many microprocessors have a
specified
operating range for supply voltage. If the microprocessor is operated outside
of this range,
then errors are likely. Thus, the shut-down threshold is established such that
it is equal to or
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slightly higher than the lowest acceptable operating voltage of the
microprocessor 555,
according to the microprocessor's specifications as indicated by its
manufacturer. It is
possible for the shut-down threshold to be set lower than such minimum
voltage, but doing so
may increase the risk of error.
[0148] If the measured voltage falls below the shut-down threshold, then
the power
management circuit 525 has discharged to the extent that continued operation
in the absence
of another electrical pulse from the generator 334 is undesirable. In such
case, the control
logic 580 initiates an orderly shut-down of the control circuitry 540 and, in
particular, the
microprocessor 555 such that continued operation of the microprocessor 555 at
voltages
outside of the desired operating range of the microprocessor 555 is prevented.
Once the shut-
down of the microprocessor 555 is complete, the microprocessor 555 no longer
draws
electrical power.
[0149] In addition, the control logic 580 may be configured to take other
actions
based on the measured voltage of the power management circuit 525. For
example, in one
embodiment, the control logic 580 is configured to delay or prevent an
adjustment of valve
position based on the measured voltage. In this regard, as the capacitor 525c
discharges, the
measured voltage (which is indicative of the amount of available power
remaining) may fall
to a level that is above the shut-down threshold but nevertheless at a level
for which the shut-
down threshold will likely be passed if an adjustment of valve position is
allowed. In this
regard, performing an adjustment of the valve position consumes a relatively
large amount of
electrical power compared to other operations, such as reading sensors 299a,
299b, 342. As
described above, to change valve position, the motor 244 is actuated such that
the COS 164 is
driven to an appropriate position in order to effectuate a desired valve
position change. If the
voltage of the power management circuit 525 is close to the shut-down
threshold before a
valve position adjustment, then the power usurped by the motor 244 in
effectuating the valve
position adjustment may cause the voltage of the power management circuit 525
to fall
significantly below the shut-down threshold.
[0150] In an effort to prevent the capacitor voltage from falling
significantly below
the shut-down threshold, the control logic 580 compares the measured voltage
of the power
management circuit 525 to a threshold, referred to hereafter as the "delay
threshold," before
initiating a valve position change. The delay threshold is lower than the
regulated voltage but
higher than the shut-down voltage. Indeed, the delay threshold is preferably
selected such
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that, if it is exceeded prior to a valve position adjustment, then the power
usurped to perform
such adjustment will not likely cause the capacitor voltage to fall
significantly below the
shut-down threshold.
[0151] If the measured voltage is below the delay threshold but higher
than the shut-
down threshold, then the control logic 580 waits before initiating the valve
position
adjustment and continues monitoring the capacitor's voltage. If an electrical
pulse is
generated by the generator 334 before the shut-down threshold is reached, then
the pulse
should charge the power management circuit 525 and, therefore, raise the
voltage of the
power management circuit 525. If the measured voltage increases above the
delay threshold,
then the control logic 580 initiates the valve position adjustment. However,
if the measured
voltage eventually falls below the shut-down threshold, then the control logic
580 initiates an
orderly shut-down of the circuitry 540 and, in particular, the microprocessor
555 without
performing the valve position adjustment. However, it may be more desirable to
ensure that
the COS 164 is positioned in a known safe state as the last operation before
allowing any
valve movements that may cause an interruption to the control circuit. For
example, if a door
is in a closing function and the control circuitry 540 determines that there
is only enough
energy for one more COS 164 movement, so instead of moving the COS 164 into
the final
COS position before reaching full close, the last move may be to put the COS
in the ready to
open position to ensure correct functioning for the next user of the door.
[0152] As described herein, the control unit 110 can be mounted in many
orientations
with respect to the door closer 90 with a variety of arm mounting options. For
example, the
control unit 110 can be mounted on top of or on bottom of the door closer 90.
Further, the
components of the control unit 110 are designed to be operable for multiple
orientations of
the control unit 110 with respect to the pinion 112. In one embodiment, the
control unit 110
is secured to the door closer via screws, which pass through the control unit
110 and into the
door closer 90. Whether the control unit 110 is mounted on the top or bottom
of the door
closer 90, the same side of the control unit 110 abuts the door closer 90 such
that the large
opening defined in the cover receives the end of the pinion 112. That is, the
control unit 110
is rotated 180 degrees when changing the mounting from the top of the door
closer 90 to the
bottom of the door closer 90 or vice versa. In other embodiments, other
techniques and
orientations for mounting the control unit 110 are possible.
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[0153] When the control unit 110 is mounted on one side (e.g., top) of
the door closer
90, the pinion 112 may rotate in one direction (e.g., clockwise) relative to
the large drive gear
302 when the door is opening, but when the control unit 110 is mounted on the
opposite side
(e.g., bottom) of the door closer 90, the arm shaft may rotate in the opposite
direction (e.g.,
counter-clockwise) relative to the large drive gear 302. The control unit 110
is operable
regardless of whether the pinion 112 rotates clockwise or counter-clockwise
when the door is
opening.
[0154] Once an installer has mounted the door closer assembly 80 for
whatever
orientation desired, the control logic 580 must be taught the specifics of the
relative final
angular displacement that the control unit 110 will see during operation. In
particular, the
control unit 110 must know if the door closer assembly 80 is mounted as a
parallel mount, top
jamb mount, or normal mount, whether the swing of the door is left-handed or
right-handed,
and then the corresponding closed position of the door 82 as well as the 90
degree open
position. This is because the range of angular displacement of the arm encoder
gear 336 will
differ for each installation. In addition, installers may choose varying
physical locations even
within these mounting options. The end result of such a variety of possible
installation
orientations is that the overall angular displacement of the pinion 112 during
door operation
will vary such that any set parameters for where threshold data 590 has
predetermined a
change in COS 164 positioning may not be correct for the expectations of the
user.
[0155] In one embodiment, a teach button assembly provides a means for an
installer
to inform the control logic 580 what configuration has been chosen to assist
in setting the
appropriate threshold data 590 for proper operation. Referring to FIGs. 38 and
42-43B, the
teach button assembly depicted includes a teach button 350 and a magnet 352.
In some
embodiments, the door closer assembly 80 can be initially pre-set as
determined by the
manufacturer as the most common mode of operation based upon market knowledge.
First
the installer is instructed to install the door closer assembly 80 as
described in installation
instructions onto a door. After installation is complete, the installer then
energizes the
electronics of the control unit 110 by opening the door and closing the door
up to three times
and then allowing the door to rest at close. Then the installer is instructed
to push the teach
button 350 a certain number of times which indicates what style of
installation the closer is in
(i.e., regular, top jamb mount, or parallel mount). In another embodiment. an
alternate
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method of indicating the style would be to use switch settings located on the
control unit 110
and accessible to the installer.
[0156] Once the style is selected, the installer then opens the door 82 to
90 degrees,
where the arm encoder gear 336, magnetic sensor 342 on the PCB 300, and
control logic 580
store the values for calibration calculations. The installer is then
instructed to release the door
82 such that when it comes to rest at the closed position the arm encoder gear
336, the
magnetic sensor which may be a Hall effect sensor 342, and control logic 580
store the values
for calibration calculations. Once the door 82 returns to the closed position,
the door closer
assembly 80 has been taught for its specific installation parameters.
Threshold data 590 is
updated and will stay constant until the teach button 350 is invoked again, as
described
above. This operation can be redone as many times as deemed necessary for
either a mistake
during the installation process, if the door closer assembly is removed and
put on another
door, or if style is changed for the existing door.
[0157] The teach button 350 is accessible in an opening in the cover of
the control
unit 110. When the teach button 350 is pushed, another magnetic sensor 354,
such as a Hall
effect sensor, on the PCB 300 will recognize that the magnetic field strength
from the teach
button magnet 352 has deviated and that the teach operation has been invoked.
Referring to
FIG. 43B, at the point that the teach button 350 is frilly depressed, the
upper arm encoder gear
331 b engages and compresses a spring 344 between the arm encoder gears 331a,
33 lb and
disengages the arm encoder gear 331b from the arm gear 336. This allows the
arm gear 336
to spring back to a home position due to a spring 337 affixed to a tab 366,
such that the one or
more magnets 340 on the arm gear 336 aligns to a zero position relative to the
one or more
sensors 342 on the PCB 300. When the teach button is released, the spring 344
acts to push
the upper encoder gear 331 b back into engagement with the arm gear 336, thus
fixing all
gears to this new known zero state. It should be understood that a known zero
state implies
that the door is in the closed position, the arm has been preloaded, and power
has been
generated for the door 82 to recognize the teach operation has been initiated.
During the next
step of opening the door 82 to 90 degrees, the arm encoder gear 336 rotates as
described
above. Specifically, the pinion 112, due to door 82 movement, rotates the
large drive gear
302. The lower gear of the drive gear 302 engages and rotates the lower arm
encoder gear
331a. Rotation of the lower arm encoder gear 331a rotates the upper arm
encoder gear 331b.
The upper arm encoder gear 33 lb engages and rotates the arm gear 336, which
changes the
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relative position of the magnet 340 and the sensor 342. The control logic 580
monitors this
activity and calibrates the ratiometric readings for both the zero position
and the 90 degree
position of the door 82, along with physical characteristics of known angular
distances for a
full sweep of 90 degrees, such that now COS 164 threshold data 590 can be
augmented for
the specific installation.
[0158] In additional embodiments, the teach mode of a door closer may
follow the
process illustrated in FIG. 44. FIG. 44 is a flowchart that is presented as
FIG. 44A, FIG.
44B, and FIG. 44C for clarity. Like many flowcharts, FIG. 44 illustrates the
method or
process as a series of process or sub-process blocks. The teach mode process
2100 begins in
this embodiment at block 2102. At block 2104, user interface switches are read
by the
controller to determine the installation configuration. At block 2106 of FIG.
44A, the user
opens and closes the door to power the controller. At block 2108, the control
circuitry detects
that the user has pressed the teach button of the door closer with the door at
jamb position.
At block 2110, the user opens the door at least past the 45 degree position,
in most cases,
following instructions supplied with the door closer. The arm gear 336 is
monitored at block
2112 and values are stored in memory as variable ADX. Alternately, at some
time interval,
for example, 100ms, the arm gear 336 is monitored and a second value is stored
in memory
as variable ADN at block 2114. Processing then proceeds as indicated by off-
page connector
2116, to incoming off page connector 2118 in FIG. 44B.
[0159] Continuing with FIG. 44B, a determination is made at block 2120 as
to
whether ADN is greater than ADX while the door is opening. If so, it is
determined that the
door must be mounted for left handed opening, and a value indicating this is
stored at block
2122. The two variables are set to be equal at block 2124 and at block 2126,
the second
variable is again updated after a time delay. The variables are compared again
at block 2128.
If the value of the second variable has increased at decision block 2128, it
is determined that
the door is still opening at block 2130 and this part of process 2100 repeats.
Otherwise, it can
be assumed that the door is now closing at block 2132.
[0160] Still referring to FIG. 44B, if ADN is not greater than ADX at
block 2120, the
door must be mounted for right handed operation and a value indicated this
type of swing
information is stored at block 2134. The two variables are set to be equal at
block 2136 and
at block 2138, the second variable is again updated after a time delay. The
variables are
compared again at block 2140. If the value of the second variable has
decreased at decision
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block 2140, the door is still opening at block 2142 and this part of the
process 2100 repeats.
Otherwise, it can be assumed that the door is now closing at block 2132. Note
that the
selection and naming of variables, and which one increases based on movement
of the door,
is arbitrary and will vary depending on the particular hardware and software
design of the
control unit. Once this portion of the process is completed and the door
begins to close,
processing moves to FIG. 44C via off page connector 2150.
[0161] Turning to FIG. 44C, processing picks up with incoming off page
connector
2152, where the value of the variable ADN is again updated and stored at block
2154. At
decision block 2156 a determination is made as to whether the two variables
are equal. If
not, it can be assumed that the door is still moving at block 2158, in which
case the variables
are set to be equal again at block 2160 and the variable ADN is updated again.
Otherwise, it
can be assumed that the door has reached the jamb position at block 2162, and
the value is
stored as the jamb value and checked against a stored calibration curve. If
necessary, values
can be skewed at block 2164, or an error can be reported if the value makes no
sense.
Process 2100 ends at block 2168, normally with the controller exiting the
teach mode. The
processes involved in obtaining calibration data are described below.
[0162] Due to mechanical tolerance stack up expectations, after final
assembly of the
door closer 90 and the drive unit 100, a final calibration capability can also
be designed into
the control logic 580, such that when motor calibration is invoked via a
predefined command,
the door closer assembly 80 will determine the ratiometric value seen by hall
effect sensors
299a, 299b that designate a COS 164 position for a fully opened valve and a
COS position for
a fully closed valve.
[0163] For example, in this exemplary embodiment the calibration method
would
start with a fully assembled door closer assembly either on a test bench or
installed on a door,
interconnected with an interface controller board (factory board) such that
commands can be
sent to the control unit 110 and the control unit 110 can be monitored and
controlled by an
external software application. This application can be designed to invoke the
motor
calibration via a predefined command through any standard serial communication
interface.
At such a time, the control logic 580 would prompt the user to rotate the
closer arm ninety
degrees and release, relying on the spring tension of the door closer 90 to
try and force the
arm 94 of the linkage assembly 92 to the door closed position. It should be
noted that the
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choice of 90 degrees as the amount of movement required for calibration is an
example, and
that other implementations can use other values as necessary.
[0164] The control logic 580 will then send PWM pulses to the motor 244,
such that
the motor coupler 242 turns the COS 164 coupler 240 and then an eventual
rotation of the
COS 164 with the intent of finding the fully closed position of the valve.
Control logic 580
simultaneously monitors the output data of the arm gear 336 through the hall
effect sensor
342 readings of the magnet 340. If the control logic 580 senses movement of
the arm
encoder gear 336, the control logic 580 will continue to move the COS 164 to a
more closed
position until it is determined that arm encoder gear 336 has stopped moving.
At this point,
the reading from the magnetic or Hall effect sensor 299a will be read and
stored in the
threshold table as the known, valve-closed position for the COS 164. It should
be noted that
the calibration routine may be designed to move the COS 164 multiple times
between the
open and closed positions and monitor the effects thereof for further
determination of a truly
closed position. The control logic 580 can send the COS 164 towards the full
open position
and monitor both hall effect sensors 299a, 299b in the drive unit 100 for
their minimum
sensor reading feedback change. The ratiometric readings reduce as the magnet
266 on the
motor coupler 242 gets further away from the Hall effect sensors 299a, 299b,
and there will
be a point that the values will stop changing and therefore signify a
ratiometric measurement
that will be stored for that sensor for this calibration on a particular
closer assembly. In this
manner, mechanical variations can be taken into account for the minimum and
maximum
ranges of the sensors 299a, 299b in the drive unit 100 such that final values
can be stored in
the threshold data 590. Calibration as described above includes human
intervention to move
the closer arm. However, calibration can be automated by providing mechanized,
computer-
controlled apparatus to move the door closer during calibration.
[0165] FIG. 45 illustrates how a calibration curve works. Arm positional
values for
such a curve can be stored in the memory of a controller for use in operations
such as the
teach mode. In the case of FIG. 45, calibration of the arm gear 336 is shown.
The arm gear
336 includes a North magnet 382 and a South magnet 383. These magnets interact
with
magnetic or Hall effect sensors on the PCB 300. A clockwise calibration curve
2210 and a
counter clockwise calibration curve 2212 are shown in the graph, which the
virtual jamb
position 2220 residing at or near the middle of both curves. For a right hand
opening door,
the right side of the graph is used, as is the part of the arm gear 336 shown
on the right. For a
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left hand opening door, the left side of the graph is used, as is the part of
the arm gear 336
shown on the left. The PCB 300 and the arm gear 336 are shown aligned with the
graph for
clarity.
[0166] It has been determined that when using an electro-mechanical
device such as
described herein to measure an angular position of a door, that it is
necessary to profile both
the opening motion and closing motion independently for the door, such that
physical door
angles can be converted into electrical A/D measurements and stored away in
memory on
main board in the form of data for curves like those shown in FIG. 45. The
reason for this
dual profile is to ensure that any mechanical gear tolerance motion deviation
when direction
of door mount is changed is accounted for. Thus, an arm gear 336 is put
through a calibration
process as described herein. The calibration curve information stored in
memory can then be
used in the teach mode previously described so that any tolerance deviations
for all mounting
options can be accounted for during normal operation.
[0167] FIG. 46 illustrates a motor encoder calibration curve made up of
valve
positional values in a manner similar to the way the arm gear 336 calibration
curve was
illustrated above. The graph shows the motor angle displacement on horizontal
or x-axis
2302 and the digital value on vertical or y-axis 2304. The graph is
superimposed over a
schematic view of the motor coupler 242 to illustrate the relationship of the
curve to physical
position. The digital value of the motor 244 may also be referred to as the
number of "clicks"
in possible movement of the motor. In this embodiment, the number of clicks
can be from
zero to 255. A maximum A/D value 2306 and a delayed action A/D value 2308 are
shown on
closed portion 2310 of the calibration curve. A minimum A/D value 2312 is
shown on the
open portion 2314 of the calibration curve. It can also be observed that in
this embodiment,
the curve crosses the y-axis at 127.5 clicks, and the displacement angle range
for the motor is
from zero to 45 degrees. Referring to the schematic diagram of the motor
coupler 242 over
which the graph is superimposed, mechanical stop 2220 is effective in the
close direction and
mechanical stop 2222 is effective in the open direction. The magnet 266 in the
drive unit,
previously discussed, is also visible, along with addition magnet, 2328.
[0168] The motor assembly 244 has its own electro-mechanical tolerance
stack up
deviation from unit to unit when installed with a particular valve assembly
120 and thus
requires a calibration for proper operation. Overall, the calibration
procedure is designed to
find a minimum A/D value. The A/D reading is a value with respect to the
relative position
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of the magnets on the arm gear 336 to the hall effect sensor on the PCB 300.
This minimum
value is what the sensor reads when the valve is in a full open position and
the maximum A/D
value can be used to close the valve completely off. Once the minimum and
maximum
values have been established, a user can be prompted to position the pinion
112 at a location
such that the spring force within the door closer 90 will try to force the
pinion 112 back to its
original starting point. As this occurs, calibration software will change the
COS 164 position
towards the maximum A/D value with the expectation that some value prior to
the maximum
A/D value will indeed stop the pinion 112 from moving back to its original
starting point.
The value determined becomes the known A/D shutoff value that can be used for
delayed
action as well as the offset for initial values for sweep and latch speeds.
The value is stored
in memory for future normal door operation.
[0169] FIGs. 47 and 48 describe calibration routines that can be partially
or fully
automated by software and can be used when a controller 110 is initially
fitted to a door
closer 90, when a controller 110 is replaced, or when a controller 110 is
retrofit to an existing
door closer 90.
[0170] FIG. 47 is a flowchart illustration of the process 2400 for arm
gear 336
calibration according to some example embodiments of the invention. Process
2400 is shown
partly in FIG. 47A and partly in FIG. 47B for clarity. Process 2400 begins at
block 2402 of
FIG. 47A. At block 2403, the arm 94 of a door closer 90 being calibrated is
moved to the
zero position. A user can move the arm 4 manually and then indicate its
position through a
connected workstation or with a button on the controller 110, for example, the
teach button
350. Alternatively, a completely computerized test bed can be used, wherein
the arm 94 can
be moved using, as an example, a robotic device. At block 2406, the zero
position is set as
the initial jamb position for the closer. At block 2408, the arm is moved
clockwise to the 270
degree position. Again, this movement, as all movements of the arm 94
described with
respect to FIG. 47, can be either by manual or automated means. This position
is then stored
at block 2410 as the maximum clockwise, or open position. The arm 94 is then
moved ten
degrees counter clockwise at block 2412.
[0171] Still referring to FIG. 47A, the current position at block 2414 is
set with the
positional value from an A/D converter in the encoder as the maximum clockwise
value
minus the result of ten degrees times the maximum counter clockwise value, and
this
positional value is stored in memory. The value in memory is incremented the
known
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amount that equates to a change in encoder output value of one unit at block
2416, and a
determination is made at block 2418 as to whether the known maximum for the
encoder has
been reached. In this particular example, the maximum value is 54. If the
value has not been
reached, the value is incremented again at block 2420 and this part of the
process 2400
repeats. Otherwise, the current position is set at the maximum
counterclockwise position and
stored in memory at block 2422, and processing proceeds to FIG. 47B via off-
page connector
2425.
[0172] Turning to FIG. 47B, process 2400 continues from incoming off-page
connector 2428. The previous process is essentially repeated for the clockwise
direction with
the movement of the arm by ten degrees at block 2430, resetting the value at
block 2432, and
determining at block 2434 if the maximum clockwise value for the encoder A/D
converter
has been reached. If not, at block 2436 this part of the process 2400 repeats.
Otherwise, all
A/D values and corresponding positions for counter-clockwise and clockwise
rotation of the
arm 94, or the pinion 112 that is coupled to the arm 94, are packed into
memory at block
2438, that is, stored in the form of a table which effectively represents the
calibration curve.
Process 2400 then ends at block 2440.
[0173] FIG. 48 is a flowchart illustrating a process 2500 for
accomplishing calibration
with respect to valve position. This process can be accomplished in parallel
or in series with
the arm calibration, and can be controlled by computer program code residing
in the control
unit 110 or elsewhere. In this example embodiment, valve position is
recognized by reading
the position of the COS 164, and the valve is moved by moving the COS 164.
FIG. 48 is
presented as Figures 48A, 48B and 48C for clarity. Process 2500 begins at
block 2502. At
block 2504, the initial A/D value is read from the valve position (COS 164)
encoder and the
COS 164 is commanded to move one increment or one "click." The COS 164 moves
one
click towards the full open position at block 2506. The initial value read
above, ADX, is
stored at block 2508, and the new value, ADN, is stored at block 2510. As long
as the
original value stays less than the new value at block 2512, the values are
equalized and the
COS 164 is moved one click and the new value stored at blocks 2514 and 2516,
respectively.
Otherwise, the last value is stored as the minimum positional value from the
A/D converter in
the encoder at block 2518, and the process continues to FIG. 48B via off-page
connector
2520.
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[0174] Turning to FIG. 48B, the process 2500 picks up from incoming off-
page
connector 2522. The COS 164 is moved by the motor one click towards the closed
position
at block 2523, and a similar process is repeated as the valve moves towards
the closed
position, with a check for movement by comparing the two values at block 2526,
a setting of
the two values as equal at block 2528, and a movement of the COS 164 by one
click at block
2530. Once the two values are equal, it can be assumed a mechanical stop has
been hit at
block 2532, and the last positional value is stored in EEPROM memory. At block
2534, the
arm 94 is rotated, either manually or under computer control, to 90 degrees to
compress the
spring 118 of the door closer 90. The valve positional value from the encoder
is read at block
2536, and the process 2500 proceeds to FIG. 48C via off-page connector 2538.
[0175] Turning to FIG. 48C, the process 2500 picks up at incoming off-
page
connector 2540. The arm is released at block 2542. The COS 164 is moved one
click
towards the closed position at block 2544. Stored positional values, in this
case, AEN and
AEX, are again checked at block 2546, in this case, to see if the values are
equal. If not, they
are set to be equal at block 2548, and the COS 164 is incremented at block
2549 and this part
of the process repeats. Once they are equal, the current positional value is
set as the value for
the closed position of the valve at block 2552, and this part of the
calibration process 2500
ends at block 2554.
[0176] Calibration as described above can be used to adjust a control
unit for a
particular closer. However, the valve position can be adjusted to maintain
appropriate
closing forces as conditions vary in the field, or based on installation.
These variations can
even result from temperature changes or normal wear and tear. Set points of
the valve can be
dynamically changed while a closer is installed to account for these
variations, thus obviating
the need to manually adjust a closer at regular intervals. This feature may be
referred to as
"dynamically adjustable valve set-points."
[0177] In addition, the latch region can be dynamically adjusted by
changing the
angle at which the latch region is encountered. In some circumstances, the
default parameters
for the final COS 164 position for close mode will not allow enough momentum
for complete
closure of a door 82. Under this condition, and, in this example embodiment,
after eight
consecutive occurrences, the control logic 580 will then adjust the encoder
angle that it
normally sets for the final angle of close, to occur earlier in the cycle. The
control logic 580
is preprogrammed to recognize occurrences of non-closure violations and adjust
accordingly.
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This exemplary embodiment currently uses three occurrences as the trigger
point for
adjustment to occur and then monitors for success. If problem persists, the
adjustment will
continue until adjustment reaches a predefined limit of adjustment set by the
factory. This
feature may be referred to a "dynamically adjustable latch position" or
alternatively as "latch
boost."
[0178] FIG. 49 is a flowchart that illustrates the operational method of a
controller
according to at least some embodiments of the present invention. Again, FIG.
49 illustrates
the method or process as a series of process or sub-process blocks. The
process 2600 of FIG.
49 is illustrated in six parts for clarity. The six pages of FIG. 49 on which
the six parts of the
flowchart are shown are designated as FIGs. 49A, 49B, 49C, 49D, 49E and 49F.
Various
portions of the flowchart are illustrated as connected via off-page
connectors, as is known in
the art, with each pair of connectors being designated with a letter of the
alphabet.
[0179] The process 2600 of FIG. 49 begins at block 2602. At block 2604, a
determination is made as to whether there is sufficient power to move the
motor 244 that
controls the valve. If not, the controller simply waits. If so, the
controller, at block 2606,
reads the input switches (discussed below) to determine the settings of the
door closer 90, and
reads the ambient temperature from an on-board temperature sensor. A
determination is
made at block 2610 as to whether the door 82 is opening or closing, based on
readings of the
hall effect sensors that have been previously discussed above. If the door is
opening, the
control unit sets the valve to a "safe close" position at block 2612, and the
door is monitored
at block 2614 to determine if the door reaches the set back check (BC)
position. The back
check position is where the door 82 begins to require the most force to open.
In this example,
the back check position is 65 degrees. If the door does not reach the back
check position, it
will begin to close at block 2616, with the same effect the logic as if the
door was closing at
determination block 2610. If the door does reach the back check position,
processing
continues via the off-page connector designated "A" to FIG. 49D, described in
more detail
below.
[0180] Continuing with FIG. 49 and referring to FIG. 49A, when the door is
closing it
is monitored to determine at block 2618 whether it reaches the latch position.
The latch
position is the point in the swing or movement of a door where it is close to
being closed, and
the force is reduced, both so that the door is easier to open at first, and so
that it closes with
less force and is less likely to damage the frame, injure a person who might
be in the
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doorway, and the like. By industry convention, a door closer is typically
designed so that the
latch position is when the outward edge of the door is approximately 12 inches
from the
jamb. If the door 82 does not reach latch position when closing, processing
proceeds via the
off-page connector designated "L" to FIG. 49C, to be discussed below. If the
door 82 does
reach the latch position, the sweep time is recorded in memory at block 2620.
The sweep
time is the time it takes for the door to move from the fully open position to
the latch
position. The controller sets the valve to the latch position at block 2622
and the door 82
closes towards the jamb at block 2624. Processing then moves to FIG. 49B via
the off-page
connector designated "B".
[0181] FIG. 49B processing starts with a determination at block 2626 as to
whether
the door actually reached the jamb, that is, whether the door closed the whole
way. As will
be appreciated from the discussion below, this determination is being made
before the
expiration of a time-out timer. If so, a determination is made at block 2628
as to whether the
latch angle is such that the door reached the latch region when it was nine
inches away from
the jamb. In this embodiment, nine inches is considered the smallest
acceptable latch region.
Despite the fact that the latch region is specified as distance of the edge of
the door from the
jamb, this distance may still sometimes be referred to informally as the
"latch angle." If not,
a counter stored in the EEPROM within the control unit is incremented by one
at block 2630.
This counter keeps track of how many times the door has closed successfully.
At block 2632,
a determination is made as to whether the door has successfully reached the
jamb 10 times
with the valve setting for where the latch region begins. The number of
successful closes
serves as a stored jamb success threshold. If so, the latch angle is adjusted
to subtract two
inches from the latch distance at block 2634. In either case the latch time,
that is, the time
required for the door to swing from the latch angle to jamb, is recorded at
block 2636. At
block 2638, any input switches and temperature are read by the control unit,
and processing
proceeds to FIG. 49F via the connector designated as "C" in FIG. 49B. The
switches,
described in more detail below, are set by a user and may signal the control
unit 110, for
example, what type of installation the closer is in, whether delayed action is
desired, where
the back check region should be, and the like. Note that the control unit can
take temperature
into account in setting the valve to cause the behavior indicated by the
switches.
[0182] Staying with FIG. 49B, and returning to block 2626, if the door did
not reach
the jamb at block 2626, a timer runs at block 2642. Once the timer has timed
out, a
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determination is made at block 2644 as to whether the door is at the jamb. If
so, processing
again proceeds to block 2638. If the door has not reached jamb at all, the
latch time is
invalidated at block 2646. At block 2648, the valve setting for the current
input switch
position is changed in this example embodiment by five clicks to increase
latch force, where
a "click" is the minimum increment in which the control unit 110 is capable of
adjusting the
valve. The EEPROM is also updated. In this example embodiment, an EEPROM in
the
controller stores latch region parameters. Other types of memory and other
devices can also
be used in addition to or instead of an EEPROM. At block 2650, the jamb
failure counter
stored in the EEPROM is incremented by one, and the success counter is set to
zero. At
block 2652 a determination is made as to whether eight jamb failures have been
recorded in
memory or the latch is at the minimum acceptable value. The number of jamb
failures in this
case serves as a stored jamb failure threshold. In either case, the default
valve set point is
changed to the current set point at block 2654. A determination is made at
block 2656 as to
whether the latch transition angle is such that the distance of the edge of
the door from the
jamb is 13 inches. If so, the switches and temperature are read at block 2638
and processing
proceeds via the off-page connector designated "C". Otherwise, the latch angle
is adjusted to
add two inches to the distance of the door from the jamb where the latch
region begins at
block 2658, prior to proceeding to block 2638.
[0183] Reviewing FIG. 49B, this portion of the operational flowchart for
the control
unit 110 of embodiments of the present invention illustrates the latch boost
feature previously
referred to. Latch region parameters include, but may not be limited to, the
latch region
distance and the force on the door 82 in the latch region. If the door 82 is
failing to close, the
valve position for the latch region of the door can be adjusted to alter the
force on the door
82, and the beginning of the latch region can also be adjusted up or down by
changing when
the valve moves to the appropriate set point for the latch region of the door.
The force on the
door 82 in the latch region can serve as a first setting for the latch region
from among the
latch region parameters. The latch region definition, by door angle, or by
distance of the
edge of the door 82 from the jamb, can serve as a second setting from the
latch region
parameters. These settings can be reversed or otherwise occur at different
points in the
operational process of the controller, and either one or both can be based on
a failure count or
a success count. The adjustments to these latch region parameters can be made
dynamically
and automatically, based on recorded successes or failures of the door closing
to the jamb.
Thus, as environmental conditions change, or mechanical resistance of the door
82 or door
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closer 90 change with wear, the door closer 90 self-adjusts these latch region
parameters to
maintain appropriate closing behavior for the door 82.
[0184] Turning to FIG. 49C, processing picks up at the off-page connector
designated
"L" from FIG. 49A, where the door does not reach the latch region. At this
point, the control
unit programmatically presumes that the door is being held or is otherwise
being prevented
from closing normally. At block 2660, if a timer that checks for the maximum
acceptable
sweep time times out, that maximum acceptable sweep time is invalidated at
block 2662. In
either case, at block 2664, the controller 110 begins processing to determine
how to handle
the fact that power is not being generated since the door 82 is not moving. As
long as there is
sufficient power to operate the control unit, processing continues via the
connector
designated "M" to FIG. 49A where sweep time is monitored. Once there is not
enough
power to run the controller beyond a single move of the COS 164, the
controller invalidates
the current sweep time measurement at block 2666 and moves the valve to a safe
close
position at block 2668 to ensure the door closes with a small enough force so
as not to cause
injury or damage, regardless of current conditions. If the door begins to move
again a
determination is made at block 2670 as to whether it is opening or closing. If
the door is
opening, processing returns via the connector designated "D" to FIG. 49A,
where the
controller determines whether the door reaches the back check region. If the
door is closing, a
determination is again made at block 2671 as to whether there is enough power
to begin to
move the motor controlling the valve again. If not, the door safely closes at
block 2672.
Otherwise, processing returns to FIG. 49A at the connector designated "E"
where the
controller monitors the sweep and determines when/if the door reaches the
latch position.
[0185] Process 2600 in FIG. 49D picks up with the connector designated
"J" which
leads from FIG. 49E, described in more detail below. FIG. 49D shows the part
of the process
that takes place when a closing door begins to open again, AND when the door
closer is
installed in a parallel mount configuration. As is known in the door closer
art, door closers
can be installed in different configurations. The configuration known as the
"parallel mount"
configuration refers to the configuration where the door closer is installed
on the push side of
a door. In this case, the door closer arm 94 rests parallel to the door when
the door is closed.
[0186] Still referring to FIG. 49D, at block 2674, a determination is
made as to
whether the door has begun to close. If not, a determination is made at block
2676 as to
whether the door angle is greater than seventy degrees. If so, processing
proceeds back to
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FIG. 49E via the connector designated "H". Otherwise, a determination is again
made at
block 2678 as to whether there is sufficient power to continue to operate the
control unit 110.
If so, the control unit 110 continues to programmatically monitor for the door
82 beginning to
close. If there is insufficient power, as before, the valve is moved to a safe
close position at
block 2680. If the door actually begins to close at block 2674, a
determination is also made
as to whether there is sufficient power to run the control unit at block 2682,
and if not, again,
the valve is moved to the safe close position at block 2680. If the valve in
the door closer 90
is in the safe close position and the door starts to close at block 2684, the
power status of the
control unit 110 continues to be monitored at block 2686. In either case, if
there is sufficient
power to run the control unit 110, the temperature and input switch positions
are checked at
block 2688, and the valve is set to the close position indicated by the input
switches and the
temperature at block 2690, and processing returns to FIG. 49A via the
connector designated
[0187] Staying with FIG. 49D, processing can pick up at the connector
designated
"A" from FIG. 49A, where the door reaches the back check region, such as at an
angle of 65
degrees. If there is sufficient power to move the valve at block 2692, the
valve is set for the
back check region at block 2694 as indicated by the appropriate input switch.
Otherwise,
processing proceeds to block 2674. It cannot be overemphasized that the
positions of input
switches, as well as the temperature, can change in the field, while the door
closer 90 is
installed, and the control unit 110 can adapt to set the single rotary valve
to an appropriate
position for the various operating regions of the door with a door closer 90
according to an
embodiment of the invention. Thus, multiple, manually adjusted valves need not
be used.
Various door closer parameters can be taken into account, and changes in those
parameters
made in the field can be taken into account. As an example, door closer
parameters include
where the back check region begins, whether delayed action is selected and the
time period
for delayed action desired, and installation configuration. While not user
configurable in the
field in the exemplary embodiments described herein, latch times and regions,
forces, sweep
times, and the like may also be considered door closer parameters.
[0188] FIG. 49E describes the portion of process 2600 that deals with so-
called
"delayed action" (DA) of the door closer 90. DA can be turned on for the door
closer of the
present embodiment by setting one of the input switches. With DA, the door
pauses in an
open position for a set amount of time prior to closing. The door closer of
the present
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embodiment does not need any additional valves to implement this feature. The
control unit
110 simply determines if the feature is turned on and closes the valve
accordingly at, and for,
the appropriate time. The control unit can also sense if the door is being
pushed during the
delay by sensing a voltage spike and reacting accordingly, adjusting the valve
to allow the
door to close without damaging any of the hydraulic components of the door
closer.
[0189] Processing picks up in FIG. 49E at the connector designated "H"
from FIG.
49D. At block 2696 a determination is made as to whether the input switch for
DA is set to
indicate that DA is desired. In this example embodiment, the switch has three
positions
(detents) one for DA off, and two for DA on, each one specifying a different
hold time. If
DA is not selected, processing proceeds to block 2698 where the valve is set
to the
appropriate close position. If so, however, a determination is made at block
2601 as to
whether there is enough power for DA. If not, processing again moves to block
2698. If
there is enough power, the valve is closed to stop movement of hydraulic fluid
in the door
closer at block 2603. At block 2605, a determination is made as to whether the
door has been
holding for the amount of time dictated by the input switch. If not, the
available power is
monitored at block 2607. If either the time has run, or there is insufficient
power, processing
immediately proceeds to block 2698. Otherwise, the door is monitored as
mentioned above
for a voltage spike at block 2609, and if a spike is detected, processing
again proceeds to
block 2698. If the door closes without changing direction at block 2611,
processing returns
to FIG. 49A at the connector designated "I". Otherwise, if the door closer is
in a parallel
mount application at block 2615, as determined by reading the appropriate
input switch
during set-up in teaching mode, processing returns to FIG. 49D via the
connector designated
"J". If the door closer is not installed in a parallel mount application,
processing returns to
FIG. 49A via the connector designated "K".
[0190] FIG. 49F continues the process 2600, illustrating another aspect of
the
previously discussed "latch boost" feature. In this case, latch parameters are
adjusted to
maintain the appropriate latch time rather than ensure the door closes to the
jamb with the
proper force. FIG. 49F also covers adjusting the sweep time based on recorded
times so that
the door closer 90 is always operating as expected, despite current conditions
and wear.
Processing picks up in FIG. 49F either from FIG. 49C at the connector
designated "F" or
from FIG. 49E with the connector designated "C". In the case of the connector
designated
"F" the control unit 110 simply proceeds to the end of the process 2600, block
2617. At
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block 2619, if the sweep time previously recorded is invalid, processing
proceeds to block
2621, where a determination is made as to whether the previously recorded
latch time was
marked in memory as invalid. Otherwise, at block 2619 a determination is made
at block
2625 as to whether the last recorded sweep time is outside of a hysteresis
range. The
hysteresis range is a sweep time slightly in excess of the maximum allowable
sweep time that
would be permitted for a single door operation from time to time, since an
excess sweep time
might result from human interference with the door, or some other completely
temporary
situation. If the sweep time is not outside the hysteresis range, processing
again proceeds to
block 2621. If the sweep time is outside of the hysteresis range, a valve
adjustment to bring
the sweep time back into range is calculated by the control unit 110 at block
2627. If the
calculated time is outside an absolute, allowable maximum at block 2629, the
sweep time is
set to the absolute maximum at block 2631. Otherwise, the calculated time is
used. In either
case, the new sweep time is stored in the EEPROM within the control unit 110
at block 2633.
[0191] Still referring to FIG. 49F, the latch time is dealt with in a
manner similar to
the sweep time above. At block 2621, if the latch time previously recorded is
invalid,
processing proceeds to block 2635, where all the latch and sweep timers are
reset for the next
time the door 82 is opened. Otherwise at block 2637, a determination is made
as to whether
the last recorded latch time is outside of a hysteresis range. The hysteresis
range for the latch
time is again simply a latch time slightly in excess of the maximum allowable
latch time that
would be permitted for a single door operation from time to time, since an
excess latch time
might result from human interference with the door, or some other completely
temporary
situation. If the latch time is not outside the hysteresis range, processing
again proceeds to
block 2635. If the latch time is outside of the hysteresis range, a valve
adjustment to bring
the latch time back into range is calculated by the control unit at block
2639. If the calculated
time is outside an absolute, allowable maximum at block 2641, the latch time
is set to the
absolute maximum at block 2641. Otherwise, the calculated latch time is used
to set the
valve. In either case, the new latch time is stored in the EEPROM within the
control unit at
block 2645.
=
[0192] Staying with FIG. 49F, a determination is again made at block 2647
as to
whether the control unit 110 has sufficient power to maintain normal
operation. If not, the
valve is moved to the safe close position at block 2649. Otherwise the, the
control unit 110
goes into a controlled sleep mode at block 2651, prior to process 2600 ending
at block 2617.
CA 02796185 2014-12-23
[0193] The foregoing description refers to input switches being read in
order to
determine parameters for the door closer 90 operation set by a user. FIG. 50
illustrates an
arrangement of user input switches that can be used with embodiments of the
present
invention. FIG. 50 shows a portion of the previously described control unit
cover onto which
a panel 2700 is fixed by screws 2701. The panel 2700 includes a plurality of
holes 2702
through which actuators 2704 protrude. Each actuator includes a detent arm
2706 which
engages with teeth (not shown) behind the panel to create a plurality of
possible rotary
positions for the actuators 2704 as indicated by numerical indicators that may
be printed or
scribed onto the panel 2700. Each actuator defines a mounting hole, into which
a magnet
2712 is secured.
[0194] Still referring to FIG. 50, a circuit board 2720 is mounted inside
the cover
behind the panel 2700. The circuit board 2720 includes magnetic sensors, such
as Hall effect
sensors (not shown), for each actuator. The hall effect sensors sense the
magnetic field of the
magnet through the cover to determine the position of actuators 2704, and
communicate this
information to the other components of the controller via the control unit
cable 292 (not
shown). In this way, switches can be provided for actuation by a user, without
additional
openings in the cover of the control unit 110 for cables or connectors.
[0195] Although the present invention has been shown and described in
considerable
detail with respect to only a few exemplary embodiments thereof, it should be
understood by
those skilled in the art that we do not intend to limit the invention to the
embodiments since
various modifications, omissions and additions may be made to the disclosed
embodiments
without materially departing from the novel teachings and advantages of the
invention,
particularly in light of the foregoing teachings. For example, some of the
novel features of
the present invention could be used with any type of hydraulic door closer.
Accordingly, we
intend to cover all such modifications, omission, additions and equivalents as
may be
included within the scope of the invention as defined by the following
claims. In
the claims, means-plus-function clauses are intended to cover the structures
described herein
as performing the recited function and not only structural equivalents but
also equivalent
structures. Thus, although a nail and a screw may not be structural
equivalents in that a nail
employs a cylindrical surface to secure wooden parts together, whereas a screw
employs a
helical surface, in the environment of fastening wooden parts, a nail and a
screw may be
equivalent structures.
56
