Control Apparatus for an Automatic Door With a Minimum Error in a Detected Door Position

1. Field of the Invention

The present invention relates to an automatic door system, and more particularly to an apparatus for controlling such a system.

2. Description of the Prior Art

A typical automatic door system has a door coupled with and driven by a belt extending from a drive pulley to its driven pulley. The drive pulley is driven by a reversible motor. Controlled rotation of the reversible motor provides automatic opening and closing of the door. In the Japanese Patent Public Disclosures 19366/80 and 28982/81, there is disclosed a prior art apparatus for controlling such a door system which employs, as means for tracking the movement of a door, a revolution sensor mounted on the shaft of the door drive motor for generating signals indicating the number of revolutions of the motor.

However, the above sensing of the door movement is an indirect one, and ignores the error in the transmission mechanism from the motor to the door to be driven. For example, a slip sometimes occurs between the shaft of the motor and a transmission mechanism in the form of, for example, a belt which extends to a drive pulley and/or between the drive pulley and a belt extending from the drive pulley and its driven pulley. Such slips introduce an error between the sensed door position and the actual door position. This might result in collisions of the door against its counterpart or a wall, or stopping of the door before it reaches its stroke end.

Further, continued running of the motor occurs when the transmission mechanism such as a belt is cut. This will burn the motor coils since the motor for driving a door is designed to be short-time rated.

With the above in mind, an object of the present invention is to provide an apparatus for controlling an automatic door system in such a manner that the detected position of the door coincides accurately with the actual position thereof.

Another object of the present invention is to provide an apparatus for controlling an automatic door system which assures that any damaging collision of the door against its counterpart is to be avoided so that the door is moved smoothly between ends of its stroke.

Another object of the present invention is to provide an apparatus for controlling an automatic door system which prevents overheating of a motor for driving the door by stopping the motor in cases where the coupling between the motor and transmission means in the form of, for example, a belt is disconnected.

In accordance with a broad aspect of the present invention, there is provided an apparatus for controlling the operation of an automatic door comprising: an electric motor; reciprocally movable driving means mechanically coupled with said motor and directly coupled to the door; sensing means relative to said movable driving means for generating pulses having a pulse repetition rate in proportion to the velocity of said movable driving means; door position detecting means electrically coupled with said sensing means for counting said pulses to obtain the current door position; and control means responsive to the obtained current door position for controlling the operation of said motor.

The above and other objects, features and the advantages of the present invention will be apparent as the description proceeds in conjunction with the drawings in which:

FIG. 1 is a schematic and block diagram of the entire automatic door system incorporating the concept of the present invention;

FIG. 2 shows part of the system in FIG. 1 illustrating a speed control of a motor for driving the door;

FIG. 3 is a perspective view of sensor arrangement which senses the motion of a driving belt directly coupled with the door in accordance with the present invention;

FIG. 4 shows a circuit diagram of a speed sensing and direction determining circuit;

FIG. 5 is a timing chart of the operation of the circuit shown in FIG. 4; and

FIG. 6 shows part of the system in FIG. 1 illustrating the main control.

FIG. 1 is a diagrammatic view of the entire door control system. A motor designated by M is coupled with a drive pulley 2 through a belt (not shown) and a reduction gear 1. A belt 4 extends from the drive pulley 2 to a driven pulley 3 and is coupled to a door 5 by means of a coupling member 6. Therefore, a forward and reverse rotation of the motor M will provide an opening and closing of the door 5.

A tacho generator 7 in the form of an alternator is coupled with the motor M to produce an output signal which passes through a rectifier and ripple filter circuit 8 to a conventional speed control circuit 9. A sensor A in the form of such as a mat switch, a photoelectric tube and so on is adapted to detect the approach of a person to the door 5 to produce and supply a signal R.sub.1 to the main control 11 which in turn will generate control signals to control the speed control circuit 9 to drive the motor M.

In accordance with the present invention there is provided a door motion sensing means 10 disposed relative to the driving belt 4. The sensing means 10 operatively produce a sensed signal indicative of the motion of the driving belt and supplies it to the main control 12 through a speed and direction detector 11.

The details of each component will now be described.

As shown in FIG. 2, the tacho generator 7 is coupled to a rotation axis of the motor M and generates an AC voltage in response to the rotation of the motor M. The generated voltage will increase and decrease in amplitude and frequency as the motor M runs at higher and lower speeds, respectively.

The rectifier and ripple filter circuit 8 comprises a diode bridge 13 adapted to provide a full-wave rectification of the output voltage from the tacho generator 7 and a ripple filter 14 adapted to obtain a smoothed DC voltage V.sub.1. The output voltage V.sub.1 is in proportion to the rotational speed of the motor M and is supplied to the speed control circuit 9.

The speed control circuit 9 includes an operational amplifier 15 adapted to amplify the resulting voltage at junction 50 determined by the output voltage V.sub.1 from the rectifier and ripple filter circuit 8 and a set voltage of V.sub.H or V.sub.L ; V.sub.H indicates a predetermined high speed while V.sub.L indicates a predetermined low speed. The output of the operational amplifier 15 is connected to a speed control pulse generator 17 adapted to generate pulses in accordance with the amplitude of the signal from the operational amplifier 15 and supply them to first and second AND gates 16.sub.1 and 16.sub.2. An operational amplifier 18 compares the voltage at junction 50 determined by the output voltage V.sub.1 from the rectifier and ripple filter circuit 8 and the set voltage of V.sub.H or V.sub.L, with the voltage at V.sub.B and generates a braking signal when the voltage V.sub.B becomes higher than the voltage V.sub.C. The braking signal is applied to a third AND gate 16.sub.3 and also to a braking pulse generator 19 which responsively produces braking pulses and applies them to the third gate 16.sub.3. A stop signal ST is used to operate a stop switch 20 so that the output voltage V.sub.1 is grounded. A signal R.sub.2 indicates a forward rotation of the motor M and is supplied to the first AND gate 16.sub.1. A signal R.sub.3 commands a reverse rotation of the motor M and is supplied to the second AND gate 16.sub.2. The output signals from the first and second AND gates 16.sub.1 and 16.sub.2 are connected to first and second OR gates 21.sub.1 and 21.sub.2, respectively. The output signal from the third AND gate is connected to both the first and second OR gates 21.sub.1 and 21.sub.2. Thus, when the forward signal R.sub.2 is generated, speed control pulses from the pulse generator 17 pass through the enabled first AND gate 16.sub.1 and the first OR gate 21.sub.1 to a gate electrode G.sub.1 of a first triac 22.sub.1 for forward rotation of the motor M. On the other hand, when the reverse signal R.sub.3 is generated, speed control pulses from the pulse generator 17 pass through the enabled second AND gate 16.sub.2 and the second OR gate 21.sub.2 to a gate electrode G.sub.2 of a second triac 22.sub.2 for reverse rotation of motor M. In this manner, the motor M is controlled to selectively run at a high speed set by the voltage V.sub.H or a low speed set by the voltage V.sub.L and to be braked by the activation of the stop switch 20 in response to the stop signal ST so that the door 5 will correspondingly move at a high or low speed and will be stopped.

FIG. 3 shows an embodiment of the motion sensing means 10 disposed relative to the drive belt 4 directly coupled to the door for generating a signal indicative of the motion of the drive belt 4. The illustrated sensing means include two optoelectronic couplers each having an optical path across the width of the drive belt. The first optoelectronic coupler comprises a first light emitting device 40.sub.1 and a first light receiving device 41.sub.1 aligned with the light emitting device 40.sub.1 along a first light path 42.sub.1. Similarly, the second optoelectronic coupler comprises a second light emitting device 40.sub.2 and a second light receiving device 41.sub.2 in alignment with the light emitting device 40.sub.2 along a second light path 42.sub.2. The illustrated drive belt 4 is a synchronous or timing belt having evenly spaced teeth 4T on the bottom surface thereof. The pitch between adjacent teeth is designated by P.

As shown in FIG. 3, the first optoelectronic coupler is spaced from the second optoelectronic coupler by a distance L along the direction of reciprocal motion of the drive belt 4. The illustrated distance L is selected at L=P.times.n+P/4 where P is the pitch between adjacent teeth of the bottom surface of the drive belt, and n is an integer (0, 1, 2 . . . ). Alternatively, the distance may be selected at L=P.times.n-P/4. In other words, the first optoelectronic coupler is out of phase with the second optoelectronic coupler by ninety degrees in terms of cyclic profile defined by the teeth of the drive belt so that when the second light path 42.sub.2 of the second optoelectronic coupler is aligned with the center 4b between adjacent teeth, the first optoelectronic coupler is positioned at the boundary between a tooth and a space.

As shown in FIG. 4, each of the light emitting devices 40.sub.1 and 40.sub.2 includes a light emitting diode LED as a light source. Each of the light receiving devices 41.sub.1 and 41.sub.2 includes a light activated or photo transistor LATR. Output signals from the first and second photo transistors are connected to the speed and direction detector 11.

The speed and direction detector 11 includes a first one shot or monostable multivibrator 43.sub.1 having an input coupled with the first photo transistor and an inhibit terminal INH coupled with the second photo transistor. The detector 11 also includes a second one shot or monostable multivibrator 43.sub.2 having an input coupled to the first photo transistor via an inverter and an inhibit terminal INH coupled to the second photo transistor. Each of the one shots 43.sub.1 and 43.sub.2 operatively generates a single pulse having a definite duration in response to a pulse at its input; however, when there is a signal at its inhibit terminal INH, this inhibits the associated one shot from generating any pulse.

The output O of the first one shot 43.sub.1 is connected to a set terminal S of a flip flop or bistable multivibrator 45 and to an input of a NOR gate 46. Tne output O of the second one shot 43.sub.2 is connected to a reset terminal R of the flip flop 45 and to another input of the NOR gate 46. The flip flop 45 operatively determines the direction of movement of the door driving belt 4 from input conditions and generates a signal R/L indicative of the direction at its output Q to supply it to the main control 12. The NOR gate 46 operatively produces a train of pulses P.sub.1 having a pulse repetition rate in proportion to the velocity of the door drive belt 4.

FIG. 5 shows a timing chart of the operation of the speed and direction detector circuit shown in FIG. 4.

When the drive belt 4 is moving in a direction as indicated by an arrow A (i.e. when the door is being advanced toward its open position), the first and second photo detectors 41.sub.1 and 41.sub.2 generate pulses occurring in a period A as shown in FIG. 5. It is noted that the pulses from the first detector 41.sub.1 are out of phase with or lead the pulses from the second detector 41.sub.2 by an angle of ninety degrees. Thus, in response to each positive-going transition of the pulses from the first photo detector 41.sub.1, one shot 43.sub.1 generates a single pulse having a definite duration at its output terminal O. However, the second one shot 43.sub.2 is inhibited by a signal to its inhibit terminal 43.sub.2 from generating any pulse at its output terminal O.

Thus, the NOR gate 46 selects pulses from the first one shot 43.sub.1 and supplies them to the main control. Similarly, flip flop 45 is set by a pulse from the first one shot to generate, at its output terminal O, a high level signal R indicative of the opening mode of the system operation (i.e. the door is being advanced toward its open position).

Conversively, when the drive belt 4 is moving in an opposite direction as indicated by an arrow B in FIG. 4 (i.e. when the door is moving back to its close position), the first and second photo detectors 41.sub.1 and 41.sub.2 generate pulses occurring in a period B as shown in FIG. 5. In this case, the pulses from first detector 41.sub.1 have a phase lag of ninety degrees relative to the pulses from the second photo detector 41.sub.2. Thus, in response to each negative-going transition of pulses from the first photo detector 41.sub.1 (each positive-going transition of pulses appearing at the input terminal I of the second one shot), the second one shot 43.sub.2 generates a single pulse having a predetermined duration at its output terminal O. However, the first one shot 43.sub.1 is inhibited since a high level or inhibit signal from the second photo detector 41.sub.2 appears at the inhibit terminal INH of the first one shot 43.sub.1 at the time of positive-going transition of the input signal thereto, thus disenabling the first one shot from being triggered. Accordingly, the NOR gate 46 selects pulses from the second one shot 43.sub.2 and supplies them to the main control, while flip flop 45 is reset by a pulse from the second one shot to generate at its output terminal O, a low level signal L indicative of the closing mode of the system operation (i.e. the door is moving back to its close position).

Referring now to FIG. 6, there the main control 12 is illustrated in greater detail. The main control 12 includes a door position measuring means 23 in the form of counter adapted to count pulses P.sub.1 having frequencies in proportion to the speed of the reciprocal movement of the door driving belt 4. The overall operation of the main control 12 is controlled by a state sequencer 24 provided therein which selectively generates a series of commands and state signals to various components in and out of the main control 12 in a predetermined sequence. The main control 12 includes a door stroke setter 25 for setting a predetermined value of the stroke of the door to be used. The door stroke setter 25 supplies the set value of stroke to the door position counter 23. Since a complete cycle of door operation comprises a door opening operation during which the door moves from one end of stroke (fully closed) to the other end of stroke (fully open) and a door closing operation during which the door moves reversely, the main control 12 includes two channels one for handling the opening mode of operation and the other for handling the closing mode of operation. Among the first channel associated with the door opening mode are a deceleration point setter 26 for setting a deceleration point when the door moves forward to open and a comparator 28.sub.1 for comparing the current door position from the counter 23 with the deceleration point from the setter 26. Similarly, the second channel associated with the door closing mode of operation comprises a deceleration point setter means 27 and a second comparator 28.sub.2.

The main control 12 further includes a pulse interval monitor or stroke end detector 29 which may comprise a counter for counting pulses from an oscillator therein adapted to generate pulses having a relatively high frequency. The counter counts pulses as supplied during one cycle of pulses P.sub.1 having frequency in proportion to the speed of the door. When the count per cycle becomes greater than a selected value, the pulse interval monitor or stroke end detector 29 signals when the door reaches the end of stroke.

Finally, a gate circuit is provided which selectively supplies high and low speed commands H and L to the speed control 9. The illustrated gate circuit includes a first AND gate 30.sub.1 adapted to receive the output of the first comparator 28.sub.1 and a forward rotation command R.sub.2 from the sequencer 24 and a second AND gate 30.sub.2 adapted to receive the output of the second comparator 28.sub.2 and a reverse rotation command R.sub.3 from the sequencer 24. The outputs of the AND gates 30.sub.1 and 30.sub.2 are connected to the OR gate 31.sub.2 which selectively generates and passes a low speed command L to the speed control 9. The output of the OR gate 31.sub.2 is also connected via an invertor to one input of a third AND gate 30.sub.3. The other input of the third AND gate 30.sub.3 is connected to an OR gate 31.sub.1 adapted to receive the forward and reverse rotation commands R.sub.2 and R.sub.3 from the sequencer 24. The third AND gate selectively generates and passes a high speed command H to the speed control 9.

The operation of the main control 12 will now be described.

When the sensor A detects the approach of a person to the door, it will generate a signal R.sub.1. Responsively, the state sequencer 24 generates a signal R.sub.4 and supplies it to the counter 23 which in turn receives a signal indicative of a predetermined stroke length of the door as set in the stroke setter 25.

At the same time, the state sequencer 24 generates a door opening signal R.sub.2 (command of the forward rotation of the motor) and supplies it to the speed control 9. The signal R.sub.2 is further supplied to the first OR gate 31.sub.1 and the third AND gate 30.sub.3 which, in turn, generates a high speed command signal H and supplies it to the speed control 9 so that the motor will accelerate and run at a high speed indicated by the command signal H in a forward direction indicated by the forward command signal R.sub.2. Thus, the door 5 will move at a corresponding high speed toward its open position.

The movement of the drive belt 4 in the direction A (corresponding to the opening direction of the door) is detected by the motion sensor 10 including two spaced photo transistors which generate first and second train of pulses having a phase relationship determined by the direction A of the belt movement. Thus, the speed and direction detector 11 determines that the door is moving toward its open position and supplies a direction signal R to put the door position counter 23 in the count down mode of operation. Further, the speed and direction detector 11 selects the first train of pulses from the first photo transistor and supplies it as a train of pulses P.sub.1 to the clock input to the door position counter 23. Responsively, the counter 23 counts the pulses P.sub.1 down from the value of stroke set in the door stroke setter 25 to obtain the current position of the door. The results of the respective counting down operations by the counter 23 are successively supplied to the first comparator 28.sub.1 which compares the successive position data each indicating the current position of the door with a deceleration point in the opening mode, as stored in the setter 26. When the current position coincides with the stored deceleration point, the first comparator 28.sub.1 generates a signal and supplies it through the AND gate 30.sub.1 enabled by the door opening signal R.sub.2 to the second OR gate 31.sub.2 to produce a low speed command signal L. Upon this signal, the motor M decelerates toward a selected low speed in a forward direction. The door 5 correspondingly is decelerated.

When the door reaches a stroke end (full open), the pulse interval monitor 29 senses it by detecting an increased interval between pulses P.sub.1 due to a decrease in the door speed, and signals to the sequencer 24.

When the door reaches a stroke end (full open), the stroke end detector 29 senses it and signals to the sequencer 24. Responsively, the state sequencer 24 generates a stop command ST and supplies it to the speed control 9 by which the motor is stopped.

Then, in accordance with its sequential logic the state sequencer 24 generates a door closing command signal R.sub.3 (command of the reverse rotation of the motor) and supplies it to the speed control 9. The signal R.sub.3 is also supplied to the second AND gate 30.sub.2 to put it in an enabled condition. Further, the signal R.sub.3 is supplied through the first OR gate 31.sub.1 to the third AND gate 30.sub.3 which, in turn, generates a high speed command signal H and supplies it to the speed control 9. Accordingly, the motor will accelerate and run at a high speed indicated by the command signal H in a reverse direction indicated by the reverse command signal R.sub.3. Thus the door will move at a corresponding high speed toward its close position.

The movement of the drive belt 4 in the direction B (corresponding to the closing direction of the door) is detected by the motion sensor 10. In response to the signals from the sensor 10, the speed and direction detector determines the direction of the movement of the door and supplies a signal L to put the door position counter 23 into the count up mode of operation. Further, the speed and direction detector 11 selects the second train of pulses from the second photo transistor and passes it as a train of pulses P.sub.1 having a pulse repetition rate corresponding to the speed of the drive belt to the door position counter 23. Responsively, the counter 23 counts up the pulses to obtain the current position of the door.

Thereafter the high speed running of the door continues until the measured current position of the door coincides with a deceleration point in the closing mode, as stored in the setter 27. Then, the second comparator 28.sub.2 generates a coincident signal which is passed through the second AND gate to the second OR gate which, in turn, generates and supplies a low speed command signal L to the motor speed control 9. The low speed running of the door under the command L continues until the door reaches the other end of stroke (full closed). Then, the motor and, therefore, the door are stopped, and the door operation is completed.

As is noted from the above, the illustrated door control system employs drive belt motion sensing means for generating pulses having a pulse repetition rate in proportion to the speed of the drive belt 4 which is "directly" coupled to the door as a final load to be controlled, and door position measuring means for counting such pulses to obtain the current position of the door. Therefore, the measured position of the door 5 coincides accurately with the actual door position. In particular, the measured door position signal does not include any error associated with a slip in a transmission mechanism between the motor and the reduction gears and a slip between the drive pulley and the drive belt. Thus collision of the door with the counterpart and/or premature stop of the door before it reaches the stroke end can be avoided so that a smooth operation of opening and closing the door may be attained.

Further, the motion sensing means (light emitting device 40 and receiving device 41) may be placed at any position in a reciprocally moving stroke or path of the drive belt 4. This will minimize the length of electric wires for connecting the motion sensing means to the speed and direction detector 11 since both of them may be built in or placed near a controller including the main control 12 disposed near the drive belt, and simplify the connection work associated therewith.

The direction detector determines whether the door is moving toward either its open position or close position. This will simplify the sequence logic used in the state sequencer 24.

In case, for example, that the door drive belt and the door are erroneously stopped because the drive belt is accidentally disengaged from the drive pulley, this is positively sensed by the pulse interval monitor 29 in cooperation with the motion sensing means and speed and direction detector, and conditions the sequencer 24 to generate a stop command ST, thus stopping the motor which would otherwise run continuously and be overheated.

Whereas a timing belt is preferred as the transmission means 4, other transmission means such as V-belt, flat belt and chain can be substituted.

Whereas the illustrated motion sensor 10 comprises optoelectronic devices, other sensing technique such as the use of magnetic sensors, contact-type sensors and iron segment sensors may be employed.

In brief, the motion sensing means may be implemented by any conventional sensor. However, it is important that such a sensor be disposed relative to a door driving member (e.g. drive belt 4) directly coupled to the door and operatively generate a signal in the form of, for example, a train of pulses having pulse repetition rate accurately in proportion to the speed of the movement of the door driving member.

While the present invention has been described with respect to the illustrated embodiment, it is to be construed that various other modifications and variations can be made well within the scope and spirit of the invention as defined in the appended claims.