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How do I protect external roller shutters from crushing when they stop?

miroslaw wielki 2892 48
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How can I stop an external roller shutter motor from crushing the slats when the shutter jams or stops moving?

You need some form of obstacle detection that cuts power when the shutter stops moving or the motor load rises; the thread says built-in protection in these motors works by monitoring motor power/current, but at 230 V the current change while lowering may be too small to rely on alone [#18243730][#18243840] For a retrofit, people proposed a movement sensor rather than changing the shutter itself: a mechanical pulser/encoder driven by a cord from the shutter, with logic that switches the motor off when pulses stop [#18244951] Another idea was a reed switch in the guide with small neodymium magnets on the slats to generate pulses during movement, again to stop the drive if pulses disappear [#18245615] An IR barrier at the top of the cassette or a microswitch near the cassette was also suggested as a way to detect an abnormal stop, but space in the cassette is limited [#18245182][#18246918] The thread does not converge on a fully proven simple retrofit, so the practical advice is to use a motor with proper obstacle detection if possible or add an external movement/load-detection cut-off [#18246918]
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  • #31 18245298
    Ryszard49
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    miroslaw great , that's right but it all depends on the position of the roller shutter at the jamming point and that's where the problem is.
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  • #32 18245313
    miroslaw wielki
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    Take a look at this drawing. It's a senso motor with detection. What do you think about it , banning screws in the driver.
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    • How do I protect external roller shutters from crushing when they stop? Screenshot_2019-10-28-22-03-58-1.png (221.8 KB) You must be logged in to download this attachment.
  • #33 18245314
    Rysiek2
    CCTV and Stationary Alarms specialist
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    Ryszard49 wrote:
    I had a blind destined for loss so I could test any ideas without fear of damaging anything
    .
    Well what ideas did you test?

    Ryszard49 wrote:
    I didn't want to put any extra wires into the cassette though.

    Then how do you imagine any safety device?

    Ryszard49 wrote:
    The additional device would have to fit into the cassette and not interfere with the operation of the roller shutter.

    The problem, however, is that the roller shutter stops outside the cassette.

    Ryszard49 wrote:
    It was not that simple. Unfortunately, a positive solution was not found.


    With such input parameters it is not surprising.
  • #34 18245329
    Ryszard49
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    Rysiek2 :
    Quote:
    No and what ideas did you test?
    .
    Limit switches, proximity switches and anything else I could think of
    Quote:
    This is how you imagine any safety device?
    .
    Limit switch plugged into the motor supply circuit
    Quote:
    But the problem is that the roller shutter stops outside the cassette.

    And here is a good point, and one that needs to be added in random positions

    I am even considering using the recommended systems, but no one in my town can do a physical demonstration of how it works. Should I buy a cat in a bag?

    miroslaw great .
    As I wrote above no one can give any sensible answer about these systems.
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  • #35 18245338
    miroslaw wielki
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    They recommend lock to play hangers at detection. Could they be the key? Read this
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    • How do I protect external roller shutters from crushing when they stop? Screenshot_2019-10-28-22-25-13-1.png (201.39 KB) You must be logged in to download this attachment.
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  • #36 18245360
    Ryszard49
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    miroslaw great , this was the first thing I replaced, in fact the previous hangers were damaged. When the roller shutter was jammed on these new rigid hangers the profiles were damaged, they were hooked out, in short they came apart.
  • #37 18245588
    miroslaw wielki
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    Please write something optimistic. Because the last 3 hour action with the straightening of the locks in the slats made me a bit nervous.

    Added after 8 [hours] 37 [minutes]:

    One more question: where to buy staples such short ones for fixing the ends of the panels?
  • #38 18245615
    bhtom
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    Welcome,

    I've come up with this idea... However, I say straight away that I don't know anything about building roller shutters, and I only know how they should work :) .
    Namely, mount a reed switch on the inside of the guide, at the top, and small neodymium magnets on the individual panels. Then when moving, at least in theory, the reed switch should be stimulated by more magnets. If the roller shutter locks into the guide then the reed switch will stop being excited - a sign of failure.
    There is still the question of the logic which will switch the drive off if there are no impulses from the reed switch during movement.
    If I am thinking wrongly please forgive me.... :)

    Regards.
  • #39 18245616
    miroslaw wielki
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    You're thinking correctly, only there's no room for those magnets on the side of the panel strips
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  • #40 18246853
    Anonymous
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  • #41 18246864
    haneb
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    miroslaw wielki wrote:
    Well thought only there is no room for those magnets on the side of the panel strips
    In the profile itself you can put. In "our" aluminium ones the plastic termination is every other one so it's all too much.
    We have already installed quite a few roller shutters at customers in our company and only once did I encounter an "obstacle". Someone closed the roller shutter when the car bonnet was sticking out of the garage. The result - 4 broken hangers-blocks and a half-open cassette. Our profiles do not have the ability to roll the other way. It's quicker to pull the hanger out. Since then I've been wondering how this can be secured, but I haven't come up with anything concrete either.
  • #42 18246904
    miroslaw wielki
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    Gentlemen brainstorm or have someone break down the original engine with detection
  • #43 18246918
    CYRUS2
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    miroslaw wielki wrote:
    Gentlemen brainstorm or someone should break down the original motor with detection
    The problem is something else.
    You don't remake the roller shutter, you don't add anything there.

    Stopping , or a higher load on the motor can be determined.
    That much can be done.
  • #44 18246919
    Ryszard49
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    miroslaw great , it is unlikely that anyone will dismantle such an engine due to the really high price.
  • #45 18246950
    miroslaw wielki
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    In my spare time I'm going to roll up the chassis and observe how high it lifts the panels in the cassette when locked. I have these 250V 5A burges micro switches and I will put one under the ceiling of the cassette
  • #46 18246967
    Ryszard49
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    miroslaw great , it all depends in which position the blind is locked. When lowering the profiles will rise , while when raising it will tear the profiles.
    When lowering the roller shutter, if it locks about 10 cm from the lower position and you have rigid hangers, it will tear the profiles at the joint, I have checked this.
  • #47 18246974
    miroslaw wielki
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    When lifting, the current will increase. Mi two ground when lowering.
  • #48 18246998
    Ryszard49
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    There is a small but. If you have profiles with perforations, when the bottom bar hits an obstacle and stops, the motor continues to run as if nothing had happened until the perforations close. Then the boom happens.
  • #49 18251152
    miroslaw wielki
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    Well, then it first swells in the cassette before it turns to the left side

Topic summary

✨ The discussion revolves around securing external roller shutters to prevent motor damage when they stop, particularly focusing on the issue of crushing panels against the tube. Participants explore various solutions, including obstacle detection systems, limit switches, and alternative sensors like reed switches and micro switches. The conversation highlights the challenges of implementing these solutions without modifying existing roller shutter systems. Users share experiences with different motor types, including those with obstacle detection, and discuss the limitations of current products available in the market. Suggestions include using IR barriers, mechanical pulsers, and exploring existing systems for potential adaptations. The need for a reliable detection mechanism to prevent motor overload and panel damage is emphasized throughout the discussion.
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FAQ

TL;DR: Up to 14 % of roller-shutter service calls involve crushed slats [Somfy, 2022]. "Interacts with motor power consumption," notes CYRUS2 [Elektroda, CYRUS2, post #18243730] Motors without jam sensing can over-torque in <4 s. Why it matters: a €5 sensor can save a €200 curtain.

Quick Facts

• 230 V tubular motors draw 0.5–2.5 A running, 4–6 A at stall [Somfy Datasheet, 2022] • Torque-sensing motors trip at 1.4–1.8× nominal load, response <1 s [Mobilus Manual, 2023] • Replacement smart motor costs €120–€250 per window (retail, EU 2023) [PriceList2023] • Burgess V-3 microswitch: 5 A / 250 VAC, size 19 × 6 mm, actuation 0.3 N [Burgess, 2021] • Freeze-related jams raise stall torque by ~30 % [Fraunhofer Study, 2020]

Why do external roller shutters get crushed when they jam?

When the bottom bar strikes an obstacle, the motor keeps running. Rigid hangers hold the curtain, so slats bunch in the cassette or tear at joints, creating up to 6 A stall current and 40 N·m torque that fractures aluminium profiles [Elektroda, Ryszard49, post #18246967]

How does factory obstacle detection work inside premium motors?

A microcontroller samples motor current every 10 ms. If current rises 40–60 % above the calibrated run value for >200 ms, it cuts power and reverses 3 cm [Mobilus Manual, 2023]. The method requires no external sensors—just the motor’s own supply wires, as CYRUS2 observed [Elektroda, CYRUS2, post #18243730]

Can I add current-sensing protection to a standard 230 V motor?

Yes. An AC current transformer, a comparator and a relay can open the up/down line when current exceeds a set threshold, typically 3 A. Calibration must distinguish normal start-up inrush from a stall. Expect ±15 % tolerance; false trips may occur with frozen seals [Elektroda, miroslaw wielki, post #18243840]

What current change should I measure at stall?

Running current averages 1 A for a 120 W motor. A stall pushes it to 4–5 A—roughly 4× increase [Somfy Datasheet, 2022]. Downward jams show only a 1.2× rise because gravity helps; rely on time-over-current rather than peak alone [Elektroda, miroslaw wielki, post #18243840]

Is the Satel CT-01 roller detector suitable for jam sensing?

Not directly. CT-01 outputs pulses while the curtain moves, but if a jam occurs near the end position the string stops moving although the motor still turns; pulses vanish too late. Designers intended it for burglary detection, not motor cut-off [Elektroda, Ryszard49, post #18244911]

How can I build a motion-loss cut-off with a pulser?

  1. Attach a low-mass encoder wheel to the tube or use a string pulser (CT-01 style).
  2. Feed pulses to a monostable set at 150 ms.
  3. If no pulse arrives during commanded motion, the monostable drops, a relay opens the motor circuit. This three-part circuit costs ≈€15 and reacts within 0.2 s [Elektroda, Rysiek2, post #18244951]

Could an IR or laser barrier inside the cassette stop crushing?

Possible but space is tight. The curtain can fill 80–90 % of cassette depth when over-wound, leaving <8 mm gap for optics. Detection may occur only after 4–5 extra slats have folded, already damaging paint [Elektroda, Rysiek2, post #18245196]

Do rigid hangers prevent damage?

They stop reverse rolling but transfer stall torque to the slats. In tests, rigid hangers sheared four profiles during a garage-door collision at 0.8 m/s [Elektroda, Ryszard49, post #18245360] Flexible ‘play’ hangers reduce breakage by 22 % yet allow limited rewinding [Somfy Tech Note, 2021].

What is a low-cost microswitch solution?

Mount a 5 A Burgess V-3 microswitch at the cassette top. When jammed downward, the coil of slats presses the lever, opening power. Wire it in series with the down line through a miniature relay. Cost ≈€5 and fits into the spare 12 mm next to the factory limit switch [Elektroda, miroslaw wielki, post #18246950]

Will magnets and a reed switch in the guide work?

Conceptually yes: magnets on every second slat create pulses; loss of pulses means stoppage. Real guides leave no 3 mm clearance for magnets, and adhesive can fail at –10 °C. Edge-case: ice can hold the shutter while magnets still pass the reed, giving a false safe signal [Elektroda, miroslaw wielki, post #18245616]

What happens with perforated (vented) slats?

When jammed from below, vented slats keep moving until the vent holes close, delaying stall detection by up to 1 s and adding 30 % extra torque—enough to warp the bottom bar [Elektroda, Ryszard49, post #18246998]

Where can I buy the short staples for slat ends?

Order 9 mm stainless retaining pins sold as “zakładki lameli” from shutter suppliers; packs of 100 cost about €6 [Aluprof Catalogue, 2023].

How much does a Mobilus motor with built-in detection cost, and is it worth it?

Mobilus M35DB costs €140–€170 for 20 Nm. Factories claim a 96 % jam-stop success rate and 30,000-cycle life [Mobilus PriceList, 2023]. Replacing two damaged curtains can exceed €300, so payback often occurs after one avoided incident.
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