Designing a Cost Effective Encoder for High Performance Doors

Abstract (Swedish)

Målet med detta arbete var att utveckla en prototyp av en kostnadseffektiv pulsgivare till motorerna för ASSA ABLOYs snabbrullduksportar. Pulsgivaren ger
återkoppling till de automatiska dörrarnas kontrollsystem och ska göra detta på ett tillförlitligt sätt samtidigt som de ska vara mer kostnadseffektiva än de nuvarande lösningarna som används på ASSA ABLOY. Utöver detta ger en egen produkt företaget mer kontroll över försörjningskedjan. Flertalet olika typer av pulsgivare har utvärderats och testats för att hitta en optimal lösning för snabbrullduksportarna i fråga, med målet att bygga en fungerande prototyp kompatibel med de nuvarande kontrollsystemen och motorerna.

Med ett, till en början brett, omfång för att utforska alla möjliga lösningar genererades koncept för de olika underproblemen i produkten. Prototyper på dessa
lösningar togs fram och testades för att sedan kombineras till en slutgiltig lösning. Den slutliga prototypen byggdes och presenteras i denna rapport.

Även om det krävs mer testning så har en lovande lösning, framtagen från en
stor mängd av koncept och teknologier, designats och testats. Den föreslagna lösningen använder optiska sensorer för och överför signaler som är kompatibla med de nuvarande kontrollsystemen och motorerna utan behov av förändring på dessa system. Utöver detta ger den värde till företaget, både i form av att den är mer kostnadseffektiv än nuvarande lösningar och genom att ge bättre kontroll över hela försörjningskedjan.

Abstract

The goal of this thesis was to develop a prototype of a cost effective encoder unit for the motors of ASSA ABLOY high speed doors. The encoder will provide feedback for the automatic doors control system and has to do so reliably while being more cost effective than the current solutions used by ASSA ABLOY as well as giving the company more control over the value chain. Multiple encoder technologies are evaluated and tested to find a solution which is most suitable for the high speed doors in question, with the aim to have a functioning prototype compatible with the current control systems and motors.

Starting with a wide scope to explore all possible solutions, concepts for the different sub-problems were generated, prototyped and tested, to then be combined into a final solution. The final developed prototype was built and is presented in this report.

While more testing needs to be done a promising solution narrowed down from
a wide variety of concepts and technologies for the encoder has been developed and prototyped. The solution proposed is an encoder utilizing optical sensors, providing signals compatible with the current control systems and motors without modification. In addition to this it would provide value for the company, not only in terms of being more cost effective than current solutions, but also giving more control over the value chain.

Popular Abstract

Automation is becoming a staple in today's society, integrating into all parts
of our everyday lives. One such implementation is in automatic doors, which calls for a connection between the physical world and digital systems. For safe and accurate operation, precise feedback from the system is crucial, which has resulted in a high interest in the field of encoders.

Efficiency and affordability are buzz-words that immediately catch the attention of any manager looking to develop their business. To achieve these goals a constant evaluation and development process is usually needed to keep up with a world that doesn’t wait for anyone. Automatic doors are crucial for efficient operations and smooth logistics, which is a pillar in modern industry. High-speed doors are often used to provide separation between rooms and climates while allowing for smooth flow of people and vehicles.

In this Master thesis a cost effective encoder for high speed doors has been
developed in collaboration with the company ASSA ABLOY Entrance Systems.

An encoder is a term used for a wide variety of sensors used to measure motion and
convert it to electrical signals. They’re used in most automatic systems from a car's cruise control, to industrial robots and automatic doors. Encoders are crucial in automatic systems and therefore in modern industry and logistics as well.

The encoder developed in this project will replace the company's current one which is both expensive and uses a lot of resources.

By testing different measurement techniques ranging from optical sensors to
mechanical and capacitive sensors a prototype was developed that uses optical
sensors to measure the speed of the door directly on the motor, allowing for higher accuracy when measuring the doors movement.

In conclusion the new prototype, if produced at full scale has the potential to cut costs as well as giving ASSA ABLOY greater control over their value chain while still keeping their high speed doors safe and reliable, opening new doors for further success.

• author: Edelstam, Emanuel and Petersson, David
• supervisor: Gunnar Lindstedt; Johan Björnstedt
• organization: Industrial Electrical Engineering and Automation
• alternative title: Design av en kostnadseffektiv pulsgivare för automatiserade rullportar
• course: EIEM01 20231
• year: 2023
• type: H3 - Professional qualifications (4 Years - )
• subject: Technology and Engineering
• keywords: Encoder, High speed doors, Motor, Product development, Prototyping, ASSA ABLOY
• publication/series: CODEN:LUTEDX/TEIE
• report number: 5494
• language: English
• id: 9129656
• date added to LUP: 2023-08-29 13:15:41
• date last changed: 2023-08-29 13:15:41