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

miroslaw wielki 2568 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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  • #1 18243009
    miroslaw wielki
    Conditionally unlocked
    External roller shutters. How do I secure the roller shutters when stopped so that the motor does not grind the panels on the tube?
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  • #2 18243568
    haneb
    Level 24  
    There are motors available with obstacle detection but I don't know how they work. Garage doors use a special bottom seal and pressure switches.
  • #3 18243635
    miroslaw wielki
    Conditionally unlocked
    Roller shutters and motors are installed. The option of replacing the motor is out of the question. How does the obstacle detection system on these motors work?
  • #4 18243730
    CYRUS2
    Level 43  
    miroslaw wielki wrote:
    How does the obstacle detection system on these motors work?
    Interacts with motor power consumption.
  • #5 18243792
    miroslaw wielki
    Conditionally unlocked
    At 230volts what interpretation is this? Need a diagram.
  • #6 18243806
    CYRUS2
    Level 43  
    Quote:
    Interpret motor power consumption.
    miroslaw wielki wrote:
    With 230volts what interpretation is that?
    How does a colleague not understand this simple text .......
    miroslaw wielki wrote:
    I need a schematic.
    Should I design this for a colleague ??? .
  • #7 18243840
    miroslaw wielki
    Conditionally unlocked
    At 230volts there is such a negligible current and a blocked going down blind does not cause much change in current. If you could design it. Incidentally, I have already tried amperometric methods but it did nothing .When pulling it up while blocked there is a current spike. When going down the motor grinds the panels.

    Added after 1 [minute]: .

    Has anyone taken apart an engine with this type of protection?
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  • #8 18243857
    Ryszard49
    Level 39  
    CYRUS2 , my saviour, I look forward to your project. I have the same problem and so far I have not found any solution in this topic. Sorry, I didn't quite find one, I just insured my external blinds. But the problem remains.
    miroslaw great , this is exactly what happened to me.
  • #9 18243866
    miroslaw wielki
    Conditionally unlocked
    I think I'll get pissed and buy a mobilus with detection and do a post-mortem. Only a couple of hundred will fly.
    Richard how did you insure? I recently had two slats damaged. Yes, the insurance is nice, but you can't match the colour. A different shade.
  • #10 18243869
    CYRUS2
    Level 43  
    Ryszard49 wrote:
    CYRUS2 , my saviour, I look forward to your project.
    After such a tone of speech, a colleague expects any help ?
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  • #11 18244720
    Ryszard49
    Level 39  
    CYRUS2 , frankly it does not. Even the companies that make such systems have options for stopping the roller shutter that are not fully worked out.
    For the record, I used part of a quote from one of the Polish TV series in part of my statement. It's a pity you didn't catch on.
    miroslaw great , I always put the damaged ones at the beginning so that they remain in the cassette. If winter comes and the panels freeze, there will be a problem again.
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  • #13 18244911
    Ryszard49
    Level 39  
    Rysiek2 , unfortunately this detector is out. It's typically used to detect attempted damage to window blinds caused by movement of the blinds due to wind, draught, and we're talking about detecting locking of the blind.
  • #14 18244951
    Rysiek2
    CCTV and Stationary Alarms specialist
    Ryszard49 wrote:
    unfortunately this detector falls off.


    Well, I believe that it should not necessarily be discarded.
    How does this marvel work? Its construction consists of a rotating mechanical pulser (interrupter) which is driven by a string connected to the roller shutter.
    This solution causes impulses to appear at the output all the time while the roller shutter is moving. It is sufficient to use this fact to build a simple electronic system detecting the absence of this movement, to switch off the roller shutter motor.
    I think that for those who have an Integra control panel, it is just a matter of programming the panel.
    I will try to develop such a system at the first free moment and in the flow of "inspiration" :) .
  • #15 18244976
    miroslaw wielki
    Conditionally unlocked
    Is this an encoder of some kind?
  • #16 18244980
    Ryszard49
    Level 39  
    Rysiek2 , I have familiarised myself with the principle of this sensor but what will it do for me as the roller shutter will lock when lowered. The motor will continue to rotate and the excess blind will "mongrel" in the cassette until the motor is stopped by the limit switch. And the fitted pulser will keep sending pulses as if nothing had happened.
    Another question is where do we mount the end of this cable that comes out of the sensor?
  • #17 18245000
    miroslaw wielki
    Conditionally unlocked
    Unfortunately this is the sad truth. Nowhere even a disassembled engine with detection in the pictures. Maybe in the Russians to look for it.
  • #18 18245008
    Rysiek2
    CCTV and Stationary Alarms specialist
    Ryszard49 wrote:
    Another question is where do we attach the end of this cable that comes out of the sensor?
    .
    Well, that's the trick. The end of this wire is attached at the bottom of the roller shutter. so when the roller shutter stops lowering, the device stops sending impulses.
  • #19 18245021
    Ryszard49
    Level 39  
    Rysiek2 , it's just a shame that these detectors have been withdrawn from sale.
  • #20 18245056
    Rysiek2
    CCTV and Stationary Alarms specialist
    Oh let's not be such malcontents :) . There are not those then there are others or there will be. The problem is indeed a serious one needs to be solved. And that is some idea.
  • #21 18245070
    Ryszard49
    Level 39  
    Rysiek2 , so far I have not found a similar solution. One has to keep on combining.
  • #22 18245072
    miroslaw wielki
    Conditionally unlocked
    Look out gentlemen
  • #23 18245082
    Rysiek2
    CCTV and Stationary Alarms specialist
    Take it easy, you have to sleep with it :) .
  • #24 18245096
    bhtom
    Level 39  
    Welcome,

    Maybe such could be adopted?
    The question of the output signal remains.

    Regards.
  • #25 18245102
    Rysiek2
    CCTV and Stationary Alarms specialist
    bhtom wrote:
    Maybe such could be adopted?
    .
    A beautiful thing but probably too expensive for such an application.
    From the parameters it seems it won't be cheap.
  • #26 18245182
    miroslaw wielki
    Conditionally unlocked
    I have a thought. When the roller shutter goes down the motor locks and the motor causes the panels to fill the whole cassette in the middle. How about an IR barrier at the top of the cassette?
  • #27 18245196
    Rysiek2
    CCTV and Stationary Alarms specialist
    miroslaw wielki wrote:
    And how about cycling the IR barrier at the top of the cassette?
    .
    That would also be a solution although I don't know if detection would be too late.
    The roller blind in the cassette takes up quite a lot of space and the barrier would have to be quite far away.
    Besides, when the roller blind is rolled up there is not much room for the barrier anymore.
  • #28 18245203
    miroslaw wielki
    Conditionally unlocked
    Or some sort of micro switch like that on top of the cassette?

    Added after 4 [minutes]:

    A little space yes , but it has no right to touch the top and when it is blocked it first unfolds and fills the cassette and when there is no space then it rewinds on the tube to the left side
  • #29 18245229
    Ryszard49
    Level 39  
    miroslaw great , I had a blind destined for loss so I could test any ideas without fear of damaging anything. However, I didn't want to introduce any additional wiring into the cassette. The extra device would have to fit into the cassette and not interfere with the operation of the roller shutter. It was not that simple. Unfortunately, I did not find a positive solution.
  • #30 18245251
    miroslaw wielki
    Conditionally unlocked
    Such a limit control is tiny and via a mini relay. And there is some space here next to the limit control.

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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