slow start n stop for gate opener

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ceolwynn

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Hi fellow enthusiast ! ,

I am bulding a gate opener circuit to drive a 1/2 hp
24 v DC motor for our vehicle gate. the gate is 12 ft
long, 7 feet tall, wide and weighs about 200 pounds.
The sudden start and stop from my controller is really
stressing out the mechanical parts. another challenge
is that it is not quite on level ground, there is a slight
downslope on the closing run so I need at least a 3
second decel from 100% to 30% to handle the down
slope additional momentum on the "close" run.

so I need to add to this, a circuit that can take
about 2 seconds to go from a .5v output, to a 10 v
output, run until a limit switch either closes or opens,
and then ramp down from the 10 v to .5 volts in
about 3 seconds.

The motor controller I am using is a Dart 65E40
and it has 2 methods of control, 100% on / 0% off,
or a 0 -to- 10 volt speed control input. at zero
volts it runs the motor at 30% and at 10volts 100%.

The annoying part is that the designers included in
this controller a 0 -to- 10 second adjustable
acceleration adjustment, but only a fixed .5 second
deceleration mode ??? rats... I tried it and it is too
short for decel to be useful on the close mode especially !

I have been studying and collecting the many
versions of the Slow on / Slow off light dimmer
controller, to see if I could use it as a staring point
but I don't have the level of design experience to
modify the existing slow on / slow off circuits to
do the ramp up / run / ramp down pattern I need.

Since I am using dual 12v bateries to run it all
I also have the option to cut-out one of the batteries
as a slow down method as well when the motor gets
shut down to only 12 volts. but even on 12v it still
needs the soft start n stop.

who might know of any basic circuits that could
do this ramp up / run / ramp down pattern ?

or maybe a few separate circuits I could run in
series ?

thanks ... // Tom \\ Dallas Texas
 
slow start n stop for gate opener - PS: -

I forgot to mention where I am at now...

I have been trying to use a quad 555 timer
with a 2 second one, and the end a 3 second one,
and using two of the quad timers as a missing pulse
detector to pick up on a closing / opening limit
switch to trigger the final 3 second ramp down
timer.

on the outputs of the ramp timers I am trying to
use a basic RC pair that can take the 2 and 3
second times to slowly saturate . it is not working
out so good

NOTE: the motor controller also has Pots for
max speed, and max amps. I have also been
experimenting with setting those Pots to Highest
settings and bridging them with lower resistance
fixed resistors which connect via limit switches I
have been double sided taping onto the limit switch
track in the drive train frame.

but this still has a jerky effect on the motor
speed and the mechanics of the drive chain .

I feel that the smoothest operation is going to
come from using the 0 -to- 10 volt speed input
build into the controller.

I am also working on a reversing circuit that
will be triggered by a garage door impact detection
strip I have attached to the leading edge of the
gate, so if it bumps anything, the gate will stop
in any position, and then restart the opposite way
until fully open again.

// Tom \\
 
Hi Tom.

Please excuse my ignorance, but how is the driver board told to start/stop/reverse/etc.? I had a quick look at a Dart 65E series brochure but could only see an on/off switch and an inhibit switch as a means to control the driver. Any chance you could draw up a quick sketch of how it's wired up?
 
... Seems like your RC pair suggestion ought to be able to assist with the 0-10 volt interface to the motor controller. ...It may not give you a precisely linear increasing ramp, but it should moderate the increasing portion of the initial gate closure.
What does your RC circuit look like .... what values are you using?

For the decel portion of the gate closure, would you be able to activate or enable a second RC circuit, as it is applied to the 0-10 volt gate signal?

You might take a look at the LT Spice circuit simulator program. This could help in determining RC values for your circuit modifications. ... Also, it is easier to see what you are doing if there is a diagram available.
 
Have you considered a dedicated motor controller? I have used the TPIC2101, and such functions are effectively built in and controlled with resistors. I suspect there are newer chips available.

As for stopping under load, I had a 50X18 ft steel bi-fold door that opened up and down. I addressed the braking mechanically by using a worm gear to belt drive for my speed reduction. The worm gear provides substantial and relatively soft self-braking.

If you want instant reversal at intermediate positions (i.e., for safety) but slow starts and stops at the end positions, a microcontroller might end up to be the easiest solution.

John
 
 
Existing Kit for Soft Start / Stop ...

 

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Ok, that manual's a bit more informative than the brochure I saw. I don't have time to work it out at the moment, but you can probably connect a resistor from U3-2 pin 5 to 12V, which will give you acceleration and deceleration control. I'd try a value between 270k and 470k for starters.
 
Better yet, replace R16 & R17 with 220k. Use a 10k pullup from U3-2 pin 5 to 12V. That should give you roughly equal acc / deacc. rates adjustable up to ~6seconds.
 
Might not work if you set the speed pot too low (i.e. <6V), but otherwise should be ok..
 
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